Gasoline Engine

Introduction...............................................................................................
01
Preparations ............................................................................................. 02
Repair Specification.................................................................................. 03
Fault Diagnosis and Troubleshooting ....................................................... 04
Usage and Maintenance of Engine........................................................... 05
Whole Engine Set..................................................................................... 06
Disassembly of Engine ............................................................................. 07
Assembly of Engine.................................................................................. 08
Mechanical System .................................................................................. 09
Electronic Fuel Injection System............................................................... 10
Lubrication System ................................................................................... 11
Cooling System ........................................................................................ 12
Air Intake and Exhaust Systems............................................................... 13
Electrical System ...................................................................................... 14
Introduction
How to Use This Manual ..............................................01-1
General.....................................................................01-1 01
Preparations .............................................................01-1
Repair Procedures....................................................01-1 02
Repair Specification..................................................01-3
Tip and Caution .................................................... …01-3 03
International System of Units (SI) ...........................01-3
Vehicle Identification Mark ...........................................01-4
04
Engine System Identification ....................................01-4
Engine Views ...............................................................01-5
View 1.......................................................................01-5 05
View 2.......................................................................01-7
View 3.......................................................................01-9 06
View 4.....................................................................01-11
General Safety Rules .................................................01-13 07
Important Safety Rules ...........................................01-13
General Repair Instructions .......................................01-15 08
General...................................................................01-15
General Cleaning Instructions ....................................01-16
09
Definition of Cleaning .............................................01-16
Sanding Abrasive Disc and Paper ..........................01-17
Gasket Surface.......................................................01-17 10
Solvent and Acid Cleaning......................................01-17
Steam Cleaning ......................................................01-19 11
Fuel System............................................................01-19
12
13
14
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Introduction - How to Use This Manual 01-1
How to Use This Manual

General
1. This Manual provides the general repair instructions for gasoline engines in the Yuling product
series, and your repair quality and efficiency will be improved according to the instructions of this 01
Manual.
Tip: 02
This Manual is one of the repair manuals for Yuling product series, and only provides the repair
instructions for gasoline engines employed in Yuling product series. 03
2. The common repair operation of gasoline engines falls into the following 3 main procedures:
• Diagnosis;
04
• Removal and installation, replacement, installation and inspection, and debugging;
• Final inspection.
3. This Manual mainly describes the first procedure “Diagnosis” (See Chapter 04 Fault Diagnosis and 05
Troubleshooting), the second procedure “Removal and Installation, Replacement, Installation and
Inspection, and Debugging”, and the third procedure “Final Inspection”. 06
4. For the following basic operations, this Manual only provides a detailed description to the repair of
key parts; however, in all practical repair operations, those operations are necessary. 07
• Clean parts removed, if necessary;
• Visual inspection. 08
Preparations 09
This Manual lists special tools, recommended tools, equipment and auxiliary materials necessary for
repair service in Chapter 02 “Preparations”, and describes their respective purposes. 10
11
Repair Procedures
1. Part drawings, which are inserted as required, provide a detailed description to the systems to which 12
the repaired parts belong.
2. Part drawings are exploded drawings that clearly describe the assembly relationship of parts. 13
14
01-2 Introduction - How to Use This Manual
Assembly Relationship of Parts
01
02
03
04
05
06
07
08
09
10
Stud Bolt, for Connection of Exhaust

1 Heat Shield Assembly, Exhaust Pipe 7
Manifold and Muffler
Internal Screen Assembly, Exhaust
2 8 Baseplate, Exhaust Manifold Cover
Pipe
3 Hexagon Nut with Flange 9 Stud Bolt
Shouldered Tap Bolt, Cylinder Head
4 10 Hexagon Nut, I Type
Cover
5 Heated Oxygen Sensor 11 Stud Bolt, Exhaust Manifold
6 Exhaust Manifold Assembly
List of Part Names
3. Where the installation procedures are just opposite to the removal procedures, this Manual only
provides a description to key parts.
4. This Manual employs illustrations for the key parts and operations in the procedures, provides a
detailed description to them, and lists operation methods, standard values and cautions.
Introduction - How to Use This Manual 01-3
5. This Manual has the illustrations the same with the similar models of engines. Under this condition,
the information provided may be inconsistent with the practical condition. However, the repair
methods are the same, and inconsistent points if any will give an additional description.
6. The procedures are described in the following order:
• Operation steps give “What to Do” and “Where to Do”. 01
• Operation step titles give “What to Do”.
• Operation steps give How to “Finish the Task”, and the help information for operation such as 02
“Tip” and “Caution” is also provided.
Example:
03
What to Do
Illustration Finish the Task 04
What to Do and Where to Do
2. Install Crankshaft
(a). Install the upper shells of the main bearing shells to the 05
corresponding positions.
Tip: 06
Install the upper shells of the main bearing shells to the
corresponding positions carefully in order. Make sure that the back
of each bearing shell is clean, the upper shell of each main bearing 07
shell is in the center of the shell groove, and the upper end faces
are flush. Apply an appropriate amount of oil or equivalent on the
08
inner side of the arched surface of each bearing shell after
installation.
09
Help Information
10
11
Repair Specification
The specifications are listed in boldface letter in this Manual, and it is unnecessary for you to refer to 12
them while stopping the work on hand. Chapter 03 in this Manual also introduces the repair
specification for your quick searching.
13
Tip and Caution 14

Tip It provides an additional description, which is helpful to improve the work efficiency of repair.
Caution As represented in bold, it indicates possible damages to parts and equipment or injuries to persons.
International System of Units (SI)

The unit in this Manual is based on the international system of units (SI)
Example:
Torque: 30N•m
01-4 Introduction - Vehicle Identification Mark
Vehicle Identification Mark

Engine System Identification
01 1. Engine Identification
(a). The engine identification information is directly
02 engraved on the side (water pump side) at the front
end of the oil pan.
03 Tip:
A refers to the engine text identification information.
04
05
06
07
08
09
10
Introduction - Engine Views 01-5
Engine Views
View 1
01
02
03
04
05
06
07
08
09
10
11
12
13
14
01-6 Introduction - Engine Views
1 Intake Manifold 9 High Tension Ignition Cable Assembly

2 Suspension Assembly 10 Cylinder Head Cover
3 Drain Plug, Oil Pan 11 Filler Cap Assembly
01 4 Oil Pan 12 Front Cover
5 Driving Pulley 13 Water Pump Pulley
02
6 Oil Filter Assembly 14 Thermostat Assembly
7 Suspension Assembly 15 Generator Support
03
8 Exhaust Manifold Assembly 16 Generator Assembly
04
05
06
07
08
09
10
View 2
01
02
03
04
05
06
07
08
09
10
11
12
13
14
1 Driving Pulley 11 High-voltage Ignition Coil Assembly

2 Thermostat Assembly 12 Transmission Assembly
3 Crankcase Breather 1 13 Belt
01 4 Filler Cap Assembly 14 Oil Pan
5 Crankcase Breather 2 15 Oil Pressure Warning Unit Assembly
02
6 Cylinder Head Cover 16 Starter Assembly
7 Fuel Rail Assembly 17 Suspension Assembly
03
8 Fuel Injector 18 Crankcase
04 9 High Tension Ignition Cable Assembly 19 Exhaust Manifold Assembly
10 Fuel Pressure Regulator 20 Heated Oxygen Sensor
05
06
07
08
09
10
View 3
01
02
03
04
05
06
07
08
09
10
11
12
13
14
1 Transmission Assembly 11 Thermostat Assembly

2 Crankshaft Position Sensor 12 Belt
3 Ignition Coil Assembly 13 Oil Pan
01 4 Fuel Pressure Regulator 14 Crankcase
5 Valve EGR 15 Suspension Assembly
02
6 Fuel Rail Assembly 16 Heater Water Pipe
7 Intake Manifold 17 Inlet Hose
03
8 Throttle Body Assembly 18 Generator Assembly
04 9 Air Charge Pressure/Temperature Sensor 19 Driving Pulley
10 Crankcase Breather
05
06
07
08
09
10
View 4
01
02
03
04
05
06
07
08
09
10
11
12
13
14
1 Transmission Assembly 13 Belt

2 Starter Assembly 14 Crankshaft Position Sensor
3 Ignition Coil Assembly 15 Air Charge Pressure/Temperature Sensor
01 4 Fuel Pressure Regulator 16 Valve EGR
5 Cylinder Head 17 Throttle Body Assembly
02
6 Cylinder Head Cover 18 Water Temperature Sensor
7 Electromagnetic Fuel Injector 19 Suspension Assembly
03
8 Fuel Rail Assembly 20 Coolant Temperature Sensor
04 9 High Tension Ignition Cable Assembly 21 Intake Manifold
10 Crankcase Breather 1 22 Crankcase Breather 2
05 11 Filler Cap Assembly 23 Generator Assembly
12 Thermostat Assembly 24 Timing Pulley
06
07
08
09
10
Introduction - General Safety Rules 01-13
General Safety Rules

Important Safety Rules
01
Caution:
Incorrect procedures, carelessness or neglect of warnings may result in burns, cuts, physical
02
mutilation, suffocation or other personal injuries, even death.
Tip:
Prior to any repair, it is necessary to carefully read and understand all safety measures and cautions. 03
The following contents include general safety measures which must be followed in order to ensure
personal safety. Furthermore, special safety measures will be included in the practical steps. 04
1. The working area shall be dry, bright and well-ventilated, free from sundries, scattered tools, parts,
fire or other dangerous goods. Pay attention to possible dangers. 05
2. Always wear goggles and protective shoes when working.
3. Rotating parts may result in cuts, physical mutilation, or even death by rotation. 06
4. Never wear loose or broken clothes. Take off all jewels.
5. Before repair, batteries shall be disconnected (disconnect the negative cable first), and all
capacitors shall be allowed to discharge. In order to prevent the accidental start of the starter, the 07
starter shall be disconnected as well.
6. When the engine is rotated manually, only correct engine start methods can be employed. Never 08
pull or pry fans to rotate the crankshaft. Otherwise this behavior will cause serious personal injuries,
property loss or early damage to fan blades. 09
7. If the engine has run for a period of time and coolant is hot, allow the engine to be cooled before
slowly loosening the filler cap to release the pressure of the cooling system. 10
8. Before any repair, hold the workpiece by an appropriate supporting block or bracket all the time.
When there is only a jack or hoisting equipment to support the workpiece, never do any work.
11
9. Before removing or disconnecting any pipelines, joints or relevant parts, make sure that air, oil, fuel
or the pressure of the cooling system is drained or released. When disconnecting any devices in the
pressure system, pay attention to possible pressure. Never check pressure leakage by hand. 12
High-pressure or fuel may cause personal injuries.
10. In order to reduce the possibility of mutilation or frozen injury, wear protective clothing, and 13
disconnect the liquid refrigerant (freon) pipeline only in a well-ventilated working area. In order to
protect the environment, appropriate equipment must be employed for the emptying and filling of the 14
liquid refrigerant system, and this device shall be capable of preventing refrigerant gas
(fluorocarbon) from going into the air.
11. For parts with a weight of above 23kg, in order to reduce the possibility of personal injuries, hoist
them by hoisting equipment or with the help of others. Make sure that all equipment, such as chains,
hooks or hangers are in good condition and have enough bearing capacity. Confirm that hooks are
in correct hoisting positions. Support the work with crossbars all the time, if necessary. Hooks are
unable to bear lateral load.
12. Anti-corrosive agent (a component in SCA and oil) contains alkali. Never allow it to go into eyes,
avoid long-term repeated skin contact with it, and never eat it. In case of skin contact, wash the skin
with soap and water immediately. In case that it comes into eyes, wash eyes with enough water for
at least 15min immediately, and seek medical advice immediately. Place it in such a place that
children are unable to reach.
13. As both naphtha and MEK are inflammable, special attention must be paid to them. Use of naphtha
and MEK must be subject to the instructions for use from the manufacturer to ensure safety. Place
them in such a place that children are unable to reach.
14. In order to reduce the possibility of burns, pay attention to not touching hot parts, hot liquid in the
pipelines and pipes, and the engine room.
15. Use tools in good condition all the time. Before any repair work, make sure that you know how to
use those tools. Only use parts provided by Foton Automobile.
01-14 Introduction - General Safety Rules
16. When replacing fasteners, use fasteners with the same part No. (or equivalent) all the time. If
replacement is needed, never use fasteners with inferior quality.
17. When normal work can not be done due to drinking or taking medicine, never do any repair work.
18. It has been proved that used oil is carcinogenic and has reproductive toxicity. Avoid inhaling oil
01 steam, wrongly eating and touching used oil for a long time.
19. Liquefied petroleum gas (LPG), as heavier than air, gathers on the flooring, oil trap or low areas.
02 20. Natural gas (NG), as lighter than air, gathers below the engine hood and sunroof.
21. In order to reduce the possibility of mutilation or frozen injury, wear protective clothing, and
disconnect the NG or LPG pipeline only in a well-ventilated area.
03
22. Coolant is toxic. If it is disused, its disposal shall be subject to the local environmental protection
regulations.
04 23. Catalyst contains urea. Never allow it to go into eyes. In case of contact, wash eyes with enough
water for at least 15min immediately. Avoid long-term repeated skin contact with it. In case of skin
05 contact, wash the skin with soap and water immediately. Never eat it. If inhaling catalyst, seek
medical advice immediately.
06 24. As catalyst contains vanadium pentoxide, wear gloves and goggles all the time when dealing with it.
Never allow it to go into eyes. In case of contact, wash eyes with enough water for at least 15min
07 immediately. Avoid long-term repeated skin contact with it. In case of skin contact, wash the skin
with soap and water immediately.
25. Catalyst matrix contains vanadium pentoxide. If it is replaced, its disposal shall be subject to the
08 local environmental protection regulations.
09
10
Introduction - General Repair Instructions 01-15
General Repair Instructions

General
01
1. Follow all safety rules referred to in this step.
(a). Use cleaning solvents and other materials recommended by the engine manufacturer for engine
02
repair. The government shall confirm that some solvents or used oil is toxic and carcinogenic. Avoid
inhaling excessively, eating or touching those materials. Follow relevant safety regulations all the
time when using tools and equipment. 03
2. Provide a clean environment, and follow the cleaning procedures specified by the step.
(a). The engine and its parts must be kept clean for any repair. Engine or part contamination will result in 04
early wear.
3. Replace all parts or assemblies damaged or worn seriously beyond the technical 05
specification.
4. Use new genuine service parts and assemblies provided by Foton Automobile. 06
(a). Written assembly skills are provided to be applicable to parts and assemblies as many as possible.
When it is necessary to replace parts or assemblies, parts provided or recommended by Foton
Automobile must be employed in the replacement steps. 07
5. Follow the specified disassembly and assembly steps to reduce the possibility of damage to
parts. 08
09
10
11
12
13
14
01-16 Introduction - General Cleaning Instructions
General Cleaning Instructions

Definition of Cleaning
01
1. Debris on parts, which is possible to contaminate any engine systems, must be cleared away. This
does not mean that parts must be smooth and new.
02
2. It is unnecessary to sand the gasket surface to the factory-machined mark by abrasive paper, and
this is usually harmful to the sealing effect. It is important to keep the tolerance of surface roughness
03 and flatness to form a good sealing surface. Gaskets are used to make up the uneven position on
the specific surface.
04 3. If gaskets with molded edge are used, it is usually unnecessary to sand the gasket surface by
abrasive paper. Gaskets with molded edge are bonding sealing material around the edge of metal
05 sheet, and the metal-to-metal connection is formed for the metal part to achieve stability. It is better
to clear away any small amount of sealing material bonded on parts by a blunt scraper, and it is
06 unnecessary to spend time in polishing the whole surface by a automatic grinding machine or
abrasive wheel.
4. For gaskets without molded edge, nearly all of them use some material containing release agent for
07 preventing bonding. However, this does not mean that gaskets are not difficult to remove as they
have been installed for a long time and overheated or some sealant has been used to disable
08 release agent. Our purpose is that the removal of only gaskets will not cause any damage to the
matching surfaces of parts and the engine will not be contaminated (never allow tiny particles to fall
09 into the positions where they are difficult to clear away.)
5. It is unnecessary to clean the piston crown until black stains are cleared away. What needs
10 removing is carbon deposit in the top ring and ring groove.
6. It is not recommended to sand or grind the carbon ring on the top of the cylinder liner by abrasive
paper until clean metal is exposed. Otherwise, that may damage the cylinder liner, and damage any
fault evidences on the reverse indicating arrow (such as dedusting mark) of the top ring. The carbon
ring must be removed to remove the piston more easily. The rated speed shall exceed power tools
used, and high-quality medium-hard steel wire wheel can reach that speed and cause smaller
damage. After the piston is removed, broken steel wires must be looked for carefully. Steel wires
are easy to see and can be attracted by a magnet.
7. Oil on the parts removed from the engine will absorb dust in air and dirt. If possible, keep the used
oil on the part until this part is ready for cleaning, inspection and installation, and then clean that part
and clear away any dust and dirt on it. If clean a part and place it outside, clean it once more before
installation. Make sure that clean oil is used to lubricate parts before installation. It is unnecessary to
fully oil them, but do apply oil between moving parts (or before dragging the engine, conduct good
pre-filling process for the lubrication system).
8. Usually, it is unnecessary to clear away the paint on the part surface by shot blast. Parts may be
re-painted, so what to do is to clear away any peeling paint.
Introduction - General Cleaning Instructions 01-17
Sanding Abrasive Disc and Paper

1. The key point of sanding lies in “grinding”, and all engine parts will be worn down. In other words,
they are all locked together or mutually slide. Friction material and dust particles will weaken those 01
two functions
Caution: 02
The oil passage and the wear points of parts must be free from any friction material. The friction
material in the oil passage will result in bearing and bushing faults, and further cause damages
03
to the main parts as time passes, especially for main bearings and connecting rod bearings.
2. It is not recommended to sand any parts of any assembled engine or components by abrasive cloth
or abrasive paper, including but not limited to clearing away carbon deposit zone from the cylinder 04
liner, or cleaning cylinder surfaces or countersunk holes.
3. When grinding products are used to clean engine parts, especially partially assembled engine, 05
attention must be paid. There are many forms and sizes of friction cleaning products, including fine
aluminum oxide particles, emery, sand or other similar hard materials. Those fine particles are 06
harder than most of parts in the engine. As they are hard, when pressed on the soft materials, they
will damage those materials and also go into the materials. During use of those grinding products, 07
the friction cleaning products will fall from the grinding products. If the friction cleaning products are
used on the power equipment, the fine particles will thrown around the engine. If the fine particles
08
fall between two moving parts, it may cause damages to the moving parts.
4. If the diameter of fine particles is smaller the static gap (engine shutdown) between moving parts
but greater than the moving gap (engine start), the relative movement of the moving parts will cause 09
damages to parts. When the engine runs with oil pressure, fine particles with a diameter smaller
than the bearing clearance may pass through the two parts without any damages to parts, and then 10
held by the oil filter. However, fine particles with a diameter greater than the bearing clearance will
wear off the material on some part and may go into the part. Once going into one part, they will wear 11
the other part until the two parts separate without contact. If the damage has an obvious effect on oil
film, the two parts will directly come into contact, which will cause early wear or faults due to 12
shortage of effective lubrication.
5. Friction particles may fly in the course of cleaning, it is very important to prevent those fine particles
from going into the engine, whenever possible, for the oil filler and oil passage hole, especially for 13
those holes located at the downstream part of the oil filter. Plug those holes rather than trying to
blow away friction particles and debris with compressed air, because the compressed air will further 14
blow debris into the oil passage.
6. All original gasket material must be cleared away from the gasket surface of parts. However, it is
unnecessary to clean and polish the gasket surface until sanding off the machined mark. Excessive
sanding or polishing by abrasive paper may damage the gasket surface. Many novel gaskets are
with molded edge (steel base sheet with gasket bonded on it) Clear away a very small amount of
sealing material bonded on parts by a scraper or putty knife. It usually wastes time to clean the
gasket surface of a gasket with molded edge by abrasive disc or paper.
Caution:
Excessive sanding or grinding on the carbon rings on the top of the cylinder liner by abrasive
paper may damage the cylinder liner, and have it disabled. The surface layer may be damaged,
and friction particles may be pressed into the cylinder liner material, which may cause the early
wear of the cylinder or the fault of the piston ring.
7. Seal or plug all openings connected to the inside of any parts by adhesive tapes or plugs before
using abrasive disc or steel wire brush. If a power tool with abrasive disc must be employed due to
time, seal the oil passage with adhesive tape or use a plug, and clean a maximum part of the
surface by the power tool; however, clean the part of surface around the oil filler by hand to avoid
contaminating the oil passage. Then remove the adhesive tape or plug, and never use the tool to
carefully clean other areas. Never blow debris from the oil passage of the assembled engine by
compressed air. It may have an exactly opposite effect to further blow debris into the oil passage. If
both end of the oil passage are opened, the compressed air can be employed to blow the debris
away, but it is rare for an assembled engine.
01-18 Introduction - General Cleaning Instructions
Gasket Surface
1. The purpose of cleaning the gasket surface is to clear away any gasket material, but not to re-polish
01 the gasket surface of parts.
2. Liquid gasket remover of any specific brands is not recommended. If liquid gasket remover is
02 employed, check the instructions for use to make sure that the material to be cleaned will not be
damaged.
3. Pneumatic gasket scrapers can save time but attention must be paid to not damaging the surface.
03
The angulation part must be opposite to the gasket surface to prevent the blade from cutting into the
surface. Techniques and attentions are needed to use the pneumatic gasket scraper on the parts
04 made of soft material, so as to avoid damages.
4. Never scrape or brush the whole gasket surface, if possible.
05
06 Solvent and Acid Cleaning

07 1. Some solvents or acid cleaners can be employed to clean disassembled engine parts (except the
piston) The experience has shown that the best cleaning effect can be achieved provided that the
08 cleaners are heated to 90°~95°C. However, kerosene emulsion cleaners have a different technical
specification for temperature, see the following. The cleaning tank, capable of continuously mixing
09 and filtering cleaning solution, can reach the best cleaning effect. Commins does not recommend
special cleaner, and it is ok to use the cleaner according to the manual from the cleaner
10 manufacturer. Before placing parts into the cleaning tank, clear away all gasket materials, O-rings,
sludge deposit and carbon deposit from parts by a steel wire brush or scraper. Pay attention to not
damaging any gasket surface. Clean parts with steam before placing them into the cleaning tank, if
possible.
Caution:
The cleaning by solvents and acid or alkaline substances shall be subject to the methods
recommended by the manufacturer. Goggles and protective clothing shall be worn to avoid
personal injuries.
2. The experience has shown that it is best to use kerosene emulsion cleaners to clean the piston.
Those cleaners shall not be heated above 77°C. They will start to discompose above 82°C, and the
cleaning effect will weaken. Never use the solutions mainly composed of hydrochloric ether and
cresol, phenol and/or creosote. When clearing away the deposit in the ring groove, their effect is not
obvious, and the cost of correct disposal is high.
(a). The solutions with a pH above 9.5 or so make aluminum blacken, so high alkaline solutions shall not
be used.
(b). Chemical substances with a pH above 7.0 are deemed as acid substances, while chemical
substances with a pH below 7.0 are deemed as alkaline substances.
(c). The greater the pH deviation from the neutral 7.0, the stronger the alkalinity or acidity is.
3. Before placing parts into the cleaning tank, clear away all gasket materials, O-rings, sludge deposit
and carbon deposit from parts by a steel wire brush or scraper, and pay attention to not damaging
any gasket surface. Clean parts with high-temperature and high-pressure water or steam before
placing them into the cleaning tank, if possible. Removal of the thickest dirt will make the cleaner
more effective before placing in the cleaning tank, and the cleaner will last for a longer time.
4. Wash all parts with hot water after cleaning. Completely dry parts with compressed air. Blow away
water in all bolt holes and oil passages.
5. If parts are not used immediately, apply an appropriate amount of antirust, and clear away the
antirust before assembling or installing parts to the engine.
Introduction - General Cleaning Instructions 01-19
Steam Cleaning
1. Steam cleaning can clear away all forms of dirt, and the dirt will pollute the cleaning tank. It is a good
method to clean the oil passage and coolant passage. 01
Caution:
When using the steam cleaner, wear goggles or protective mask and protective clothing. 02
Otherwise, hot steam may cause serious personal injuries.
The steam cleaning is inapplicable to the following parts:
03
(a). Electrical parts;
(b). Wire harness;
(c). Fuel injector; 04
(d). Fuel pump;
(e). Belts and hoses; 05
(f). Bearings (balls or rolling cones);
(g). Electronic control modules; 06
(h). Electronic control module joints;
07
Fuel System 08
1. Before repairing any parts of the fuel system, in order to avoid contaminating those parts prior to 09
their removal, clean the surrounding area of pipe joints, mounting parts and parts to be removed. If
the surrounding area is not cleaned, dirt may go into the fuel system or the fuel system may be 10
contaminated.
2. Generally, some oil passages of the fuel injector are very narrow and tiny, and easy to jam by
contaminants. Some fuel injection systems are capable of working at very high pressure. 11
High-pressure fuel enables single dirt and rust particles to become very abrasive contaminants,
which will damage the high-pressure pumping parts and fuel injector. 12
3. Where there is no steam cleaner, electrical contact cleaner is available. When cleaning the dirt and
debris on the joints of fuel system, use the electrical contact cleaner rather than compressed air. 13
Diesel on the exposed parts of the fuel system will absorb air contaminants.
4. Select lint-free towels for the operation of the fuel system. 14
5. Once the fuel system is opened, cover or plug the fuel pipes, joints and ports. Only if the fuel pipes
or other parts is loose or removed from the engine, rust, dirt and paint may go into the fuel system.
In many instances, a good method is to loosen the pipes or pipe joints to allow rust and paint to fall
down, and then clear away those fallen materials.
6. When removing the fuel pipes or pipe joints from a new or newly-painted engine, make sure to clear
away fallen paint segments/debris, which are formed at the time when the wrench touches painted
pipe bolts or pipe joints, or when rapidly-disconnected joints are removed.
7. Tools for the fault judgment and troubleshooting of the fuel system need regular cleaning to avoid
contamination. As the same with the parts of the fuel system, tools will absorb air contaminants
when their surface is covered with oil or fuel.
8. Please remember the following points for the tools for the fuel system:
(a). Keep them as clean as possible.
(b). Clean and dry them before placing in the toolbox.
(c). Keep them in the closed container, if possible.
(d). Make sure they are clean before use.
- Memo -
01
02
03
04
05
06
07
08
09
10
Preparations
Gasoline Engine...........................................................02-1
Preparations .............................................................02-1 01
02
03
04
05
06
07
08
09
10
11
12
13
14
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Preparations - Gasoline Engine 02-1
Gasoline Engine
Preparations
Special Tools
01
02
Oil filter wrench To remove oil filter
03
04
Valve spring compressor To remove and install valve spring
05
06
Valve guide removal and installation To remove and install valve guide
punch 07
08
Intake/exhaust valve seat ring To install intake/exhaust valve seat 09

installation punch ring
10
Valve oil seal removal pliers To remove valve guide oil seal
Valve oil seal installation punch To install valve guide oil seal
Valve grinding rod and leather cuff To grind valve and valve leather cuff
(manual) (manual)
To measure the inner diameter of the

Cylinder barrel dial gauge
cylinder
Camshaft timing gear extractor To remove camshaft timing gear
Air inlet resistance watch To measure air inlet pressure

02-2 Preparations - Gasoline Engine
Puller To remove crankshaft pulley
01
02
Valve seat ring reamer components To repair valve seat ring
03
04
Piston ring remover To remove or install piston ring
05
06
07 Piston pin punch To remove piston pin
08
09
Cylinder remover To remove or install cylinder
10
Camshaft bearing shell remover To remove camshaft bearing shell
Tachometer To measure engine’s rotational speed
Cylinder pressure gauge components To measure cylinder pressure
Oil seal remover To remove oil seal
Oil seal installer To install oil seal
Piston installer To install piston assembly

Recommended Tools
Adjustable or watch-hand torque

To fasten or remove bolt
wrench 01
02
Quick wrench or long-short connecting
To fasten or remove bolt
rod 03
04
Screwdriver To remove pipe clamp
05
06
To measure the inner and outer
Vernier caliper
diameter 07
08
90-degree angle measurement To measure right-angle 09
10
Thermometer To test thermostat
Regulatory To measure clearance
To measure the flatness of cylinder or

Precision ruler
cylinder head
Dial indicator To measure shaft runout or clearance
To support instruction class (dial

Magnetic stand
indicator or dial indicator)
To measure the diameter and

Screw micrometer
roundness of cylinder
Horizontal jack To lift heavy objects

Scraper To clean residual gasket
01
02 Combination pliers To remove cotter pin
03
04 Copper rod To remove gear
05
06
Jack
07
08
Pry bar and jack pry bar
09
10
Hammer
Insurance iron bench To withstand the car frame
Large adjustable wrench To use together with the puller
Oil basin and cleaning brush To clean components
Wire brush To clean stains
Oil seal installer To install oil seal
Circlip clamp To remove axis circlip

To beat the weak parts or dismantling

Rubber Hammer
pistons
01
02
03
04
05
06
07
08
09
10
Equipment
To disassemble transmission or engine in the vehicle
Lifting jack
groove
01 To disassemble transmission or engine in the vehicle
Horizontal jack
groove
02
Crankshaft grinding machine To grind crankshaft journal
03
valve light grinding machine To grind valve working surface
04
Air compressor To clean engine parts
05
Fuel pump efficacy test machine To test fuel pump efficacy
06
07 Auxiliaries
08 Engine lubricating oil To lubricate engine frication parts
09 Valve grinding paste To grind valve and valve seat ring
10 Prussian Blue To check the tightness between valve and valve seat ring
Thin fuse wire To check the bearing radial clearance

Repair Specification
Basic Data....................................................................03-1
LJ465Q3-1AE .........................................................03-1 01
Repair Data ................................................................03-2
LJ465Q3-1AE .........................................................03-2 02
EFI System Operating Parameters .............................03-7
LJ465Q3-1AE .........................................................03-7 03
Torque Requirements ...............................................03-10
LJ465Q3-1AE .......................................................03-10
04
05
06
07
08
09
10
01
02
03
04
05
06
07
08
09
10
11
12
Repair Specification - Basic Data 03-1
Basic Data
LJ465Q3-1AE
Inline four-cylinder four-stroke, water-cooled, oblique type,
Type
multi-spherical combustion chamber, single overhead 01
camshaft type, toothed belt drive, EFI, electronic control
ignition
02
Quantity of Cylinders 4
03
Cylinder Diameter 65.5mm
04
Piston Stroke 78mm
05
Compression Ratio 9:1
06
Total Piston Displacement 1.051L +

07
Firing Order 1-3-4-2 08
Max. Idling Speed 6000r/min 09
Min. Idling Speed 850 ± 50 r/min 10
Fuel Consumption 275/kw.h
Oil Fuel Consumption Ratio <1%
Oil Pressure 294 ~ 490Kpa
Rotation Direction of Crankshaft Clockwise (looking from the engine water pump)
Starting Method Electric started
Lubrication Method Pressure and splash compound
Cooling Method Forced circulation water cooling
Net Weight 98kg
Dimensions (L × W × H) 570mm × 613.2mm × 435.9mm
Nominal Power 38.5KW
Nominal Speed 5200r/min
Max. Torque (at 3000 ~ 3500 r / min) 83N • m

03-2 Repair Specification - Basic Data
Repair Data
LJ465Q3-1AE
01 Crankshaft
02 Plane Limit of Crankcase Top 0.05mm
03 Radial Runout Limit of Crankshaft Main Journal 0.06mm
04 Standard Value 0.13 ~ 0.28mm

Thrust Clearance of
Crankshaft
05 Limit value 0.35mm
06
Standard Value 2.500mm
07 Thickness of Crankshaft
Thickening 0.125mm 2.563mm
Thrust Washer
08
Thickening 0.250mm 2.625mm
09
Uneven Wear Limit of Main Journal 0.01mm
10
Clearance between Main Standard Value 0.020mm ~ 0.040mm
Journal and Main Bearing
Shell Limit Value 0.08mm
Standard Value φ49.985 ~ φ0.000mm
Main bearing shell diameter

φ49.735 ~ 49.750mm
reduced by 0.25mm
Diameter of Main Journal
Main bearing diameter
φ49.485 ~ φ49.500mm
reduced by 0.50mm
Clearance between the
reduced-type main bearing 0.020 ~ 0.070mm
shell and main journal
Surface Burn Limit of Flywheel 0.2mm
Piston and Connecting Rod
Standard φ65.465 ~ φ61.495mm

Piston Diameter
Extra-Large φ69.965 ~ φ62.995mm
Standard 0.03 ~ 0.07mm

Ring Gap in Top
Compression Ring Groove
Limit Value 0.12mm
Ring Gap in Second Standard Value 0.02 ~ 0.06mm

Compression Ring
Groove Limit Value 0.10mm
01
Piston Ring Thickness of Top Compression Ring 1.47 ~ 1.49mm
02
Piston Ring Thickness of Second Compression Ring 1.47 ~ 1.49mm
03
Piston Ring Thickness of Oil Scraper Ring 0.45mm
04
Piston Ring Groove Width of Top Compression Ring 1.52 ~ 1.54mm
05
Piston Ring Groove Width of Second Compression Ring 1.51 ~ 1.53mm
06
Piston Ring Groove Width of Oil Scraper Ring 2.82 ~ 2.83mm
Opening Clearance 07
Standard Value 0.15 ~ 0.35mm
between Top and
Second Compression
Limit Value 0.7mm
08
Rings
Standard Value 0.30 ~ 0.90mm 09

Opening Clearance of
Combined Oil Rings
Limit Value 1.8mm 10

Thrust Clearance of
Connecting Rod Big End
Limit Value 0.30mm
Width of Connecting Rod Big End 21.95 ~ 22.00mm
Width of Connecting Rod Journal 22.10 ~ 22.13mm
Bending Limit of Connecting Rod 0.05mm
Distortion Limit of Connecting Rod 0.10mm
Clearance between Standard Value 0.003 ~ .016 mm

Connecting Rod Small
End Hole and Piston Pin Limit Value 0.05mm
Clearance of Small End Hole φ16.003 ~ φ16.011mm
Piston Diameter φ15.995 ~ φ16.000mm
Clearance between Standard Value

Connecting Rod Journal
and Bearing Shell Limit Value 0.080mm
Radial Clearance of Rod Bearing Shell by Lowering One 0.020 ~ 0.070mm

Grouping
The connecting rod

bearing shell is 37.985 ~ 38.000mm
standard.
01 The connecting rod

bearing shell
Diameter of Crankshaft Connecting Rod 37.735 ~ 37.750mm
decreases by
02 Journal
0.25mm.
The connecting rod

03
bearing shell
37.485 ~ 37.500mm
decreases by
04 0.50mm.
Cam
05
Limit of Camshaft Linearity 0.10mm
06
Height of Intake Cam
07 Limit Value 36.100mm

08 Height of Exhaust Cam
Limit Value 36.100mm
09
Height of Gasoline Pump Eccentric Cam
10 Limit Value 33.000mm

Thrust Clearance of Cam
Limit Value 0.300mm

Radial Clearance of Camshaft Journal
Limit Value 0.15mm
Cylinder
Extra-large Piston 0.25mm/0.50mm
Limit of diameter difference between Any Two Cylinder Holes 0.05mm
Fit Clearance between Piston and Cylinder Hole 0.040 ~ 0.050mm
Rocker Arm
Standard Value
Diameter of Rocker Arm
Limit Value –
Standard Value
Diameter of Rocker Arm Shaft
Limit Value -
01
Intake
02
Limit Value 0.07mm
Clearance between Rocker 03
Arm and Rocker Arm Shaft
04
Exhaust
Limit Value 0.01mm 05
Linear Limit of Rocker Arm Shaft 0.06mm 06
Cylinder 07
Standard Value 1.324Mpa 300r/min 08
Pressure of Cylinder
09
Limit Value 1.176Mpa 300r/min
10
Pressure Difference ≥ 0.098Mpa 300r/min
Valve
Intake
Specified Valve Clearance 0.13 ~ 0.18mm
Exhaust
Standard Value
Diameter of Intake Valve Stem
Limit Value -
Standard Value
Diameter of Exhaust Valve Stem
Limit Value -
Standard Value
Diameter of Intake Valve Guide
Limit Value -
Standard Value 0.020 ~ 0.050 mm

Fit Clearance of Intake Valve Guide
Limit Value 0.070mm
01
Standard Value 0.030 ~ 0.060 mm
02 Fit Clearance of Exhaust Valve Guide
Limit Value 0.09mm
03
Terminal Deflection of Intake Valve Stem End 0.12mm
04
Terminal Deflection of Exhaust Valve Stem End 0.16mm
05
Intake
Diameter of Valve Guide Hole φ12.030~φ12.048mm
06
Exhaust
07
Extra-large Valve Guide 0.03mm
08 Protruded Height of Valve Guide 16.5mm
09 Length of Intake Valve Guide 52.5mm
10 Length of Exhaust Valve Guide 54.5mm

Thickness of Intake Valve Big End
Limit value 0.6mm

Thickness of Intake Valve Big End
Limit Value 0.7mm
Use Limit Value of Valve Stem End Face 0.5mm
Radial Runout Limit of Valve 45 º Cone 0.03mm
Intake
Color Band Width of Standard Valve Seat 1.3 ~ 1.5mm
Exhaust

Free Length of Valve Spring
Limit Value 46.5mm
Standard Value 40mm, 254.8 ~ 294N

Pre-load of Valve Spring
Limit Value 40mm, 235.2N
Verticality of Valve Spring 2.0mm

Repair Specification - EFI System Operating Parameters 03-7
EFI System Operating Parameters

LJ465Q3-1AE
Engine Control Module 01
Normal Operating Voltage 9V ~ 16V 02
Abnormal Operating Voltage 6.3V ~ 9.0V, 16V ~ 24V 03
Operating Temperature 40 ℃ ~ 85 ℃ 04
Over-voltage Protection 12V ~ 24V 05
Crankshaft Position Sensor 06
Operating Temperature -40 ℃ ~ 165 ℃ 07
Air Clearance 0.25 ~ 1.75 08
Coil Resistance 540Ω 09
Coil Inductance 240mH @ 1kHz 10
Ignition Coil Assembly
Primary Resistance 0.5Ω±0.005Ω
Secondary Resistance 5200Ω ± 400Ω
Operating Temperature 40 ℃ ~ 125 ℃
Primary Inductance 2.75mH ± 0.25mH
Secondary Inductance 17.5 ± 1.2H
Operating Voltage Range 6V ~ 16V
Secondary Output Voltage 34kV
Min. Ignition Duration 0.8mS
Coolant Temperature Sensor
Operating Voltage 5VDC
Resistance at 20 ℃ ~ 30 ℃ 3.65kΩ ~ 2.26kΩ

03-8 Repair Specification - EFI System Operating Parameters
Air Charge Pressure/Temperature Sensor
Pressure Range 15kPa ~ 102kPa

01
Operating Voltage 5V ± 0.1V
02
03
Operating Current 12mA (max)

04
05 Output Impedance <10Ω
06 Fuel Rail Assembly
07 Operating Temperature 40 ℃ ~ 115 ℃
08 System Pressure 750kPa
09
Electromagnetic Fuel Injector
10
Min. Operating Voltage 4.5V
Fuel Pressure 300kPa
Coil Resistance 12Ω ± 0.4Ω (max)
Fuel Pressure Regulator
Pressure Setting 300kPa
Operating Temperature -40 ℃ ~ 120 ℃
Valve EGR
Operating Voltage 8V ~ 16V
Voltage Limit 25V (<60S ')
Impedance 19Ω ~ 22Ω
Inductance 12mH ~ 15mH

Repair Specification - EFI System Operating Parameters 03-9
Throttle Position Sensor
Opening Range 7% to 93%

01
Operating Voltage 5V ± 0.1V
02
Operating Temperature -40 ℃ ~ 150 ℃
03
Idle Air Control Valve

04
Operating Voltage 7.5V ~ 12V 05
Voltage Limit 3.5V ~ 14V 06
Coil Resistance 53Ω ± 5.3Ω 07
Coil Inductance 33mH ± 20% mH 08
09
Oxygen Sensor
10
Max. Overheating Temperature 930 ℃

03-10 Repair Specification - Torque Requirements
Torque Requirements
LJ465Q3-1AE
01 Fasteners N•m
02 Connection Bolt, Cylinder Head 55~60
03 Nut and Bolt, Intake and Exhaust Manifolds 18 ~ 23
04 Spark Plug 20 ~ 28
05 Mounting Bolt, Camshaft Timing Gear 55 ~ 60
06 Adjustment Bolt, Valve 18 ~ 20
07 Mounting bolt, Crankshaft Pulley 55 ~ 60
08 Nut, Connecting Rod Bearing Cover 28 ~ 32
09 Bolt, Crankshaft Bearing Cover 43 ~ 48
10 Bolt, Flywheel 40 ~ 45
Bolt, Oil Pan 4~5
Drain Plug 30 ~ 35
Bolt, Cylinder Head Cover 6~8
Bolt, Front and Rear Covers 4~5
Oil Pressure Sensor 12 ~ 15
Nozzle, Oil Filter 20 ~ 25
Fixing Bolt, Rear Suspension 18 ~ 23
Spring Seat, Oil Pump Safety Valve 15 ~ 20
Fixing Bolt (L & R), Gasoline Suspension 32 ~ 38
Mounting Bolt, Tensioner 18 ~ 23
Tightening Torque, Connecting Rod Cap 28 ~ 32
Mounting nut, Camshaft Timing Pulley 50 ~ 59
Drain Plug, Oil Pan 20 ~ 25

Repair Specification - Torque Requirements 03-11
Fasteners N•m
Oil Filter 10 ~ 15
01
Stand, Oil Filter 20 ~ 25
02
Oil Pressure Warning Unit 12 ~ 15
03
Bolt, Timing Belt Pulley 3~4

04
05
06
07
08
09
10
- Memo -
01
02
03
04
05
06
07
08
09
10
Fault Diagnosis and Troubleshooting
Fundamentals of Fault Diagnosis of Gasoline Engine..04-1
Diagnosis Instructions ..............................................04-1 01
Cautions ...................................................................04-1
Fault Diagnosis and Troubleshooting of Gasoline 02
Engine..........................................................................04-2
Difficult Gasoline Engine Start ..................................04-2 03
Gasoline Engine Surge.............................................04-4
Gasoline Engine Knocking........................................04-5
04
Power Shortage in Operation ...................................04-6
Unstable Gasoline Engine Idle Speed ......................04-7
Excessive Pollutants at Idle Speed from 05
Gasoline Engine .......................................................04-9
Excessive Fuel Consumption of Gasoline Engine ..04-10 06
Internal Abnormal Noise of Gasoline Engine ..........04-11
Gasoline Engine Overheating.................................04-12 07
Excessive Oil Consumption of Gasoline Engine.....04-14
Low Oil Pressure of Gasoline Engine .....................04-15 08
Gasoline Engine Backfire .......................................04-16
Acceleration Lag of Gasoline Engine......................04-17
09
Gasoline Engine Fuel Stop and Misfire ..................04-18
Fundamentals of Fault Diagnosis of Engine EFI
system........................................................................04-19 10
Diagnosis Instructions ............................................04-19
Cautions .................................................................04-19
Fault Diagnosis and Troubleshooting of Engine EFI
system........................................................................04-21
Working Principles of Diagnosis .............................04-21
Fault Diagnosis Procedures....................................04-22
Fault Code Reading................................................04-23
Fault Code Table ....................................................04-24
Definition of MT20U Pin..........................................04-30
Inspection and Troubleshooting of Fault
Symptoms...............................................................04-34
01
02
03
04
05
06
07
08
09
10
Fault Diagnosis and Troubleshooting - Fundamentals of Fault Diagnosis of Gasoline 04-1
Engine
Fundamentals of Fault Diagnosis of Gasoline Engine

Diagnosis Instructions
01
1. Due to the wear, deformation, misuse and improper technical maintenance of parts, the technical
02
conditions of each part gradually deteriorate while the gasoline engine is working. When some
technical indexes exceed the permissible limits, it indicates that faults have occurred in the gasoline
engine. 03
2. When the gasoline engine has faults, it may not be able to work in normal conditions if the faults are
not properly resolved in time. This will not only lead to the reduction of power performance and 04
economical efficiency, the degradation of service and operating performance and the decrease in
emission level but also cause premature wear of parts. 05
3. Some faults of the gasoline engine, such as air in fuel system, filter plug, over-loose belt and so on,
can be resolved after necessary technical maintenance and adjustment, while some faults, such as 06
cylinder gasket damage, serious piston ring wear, conical surface wear of valve, excessive bearing
shell wear and so on, cannot be resolved through general maintenance and adjustment due to
defects in mechanism, but can only be resolved through dismantling the gasoline engine for repair 07
or replacing parts.
08
Cautions 09
1. The faults of gasoline engine shall be resolved in time once they occur. For the removal, the faults 10
shall be carefully checked and analyzed firstly. Never remove blindly and randomly.
2. Operating personnel shall get familiar with the structure and technical data of gasoline engine and
the assembly relations between and the technical requirements for assembly/disassembly of parts
and components and grasp correct assembly/disassembly methods and usages of tools for
overhaul.
3. Complicated fault diagnosis and solutions shall be performed with the help of instruments and
special equipment by technical personnel. If users can neither determine faults by themselves nor
have necessary technical conditions or ability in repair, please contact Foton service stations for
repair.
04-2 Fault Diagnosis and Troubleshooting - Fault Diagnosis and Troubleshooting of
Gasoline Engine
Fault Diagnosis and Troubleshooting of Gasoline

Engine
01
Difficult Gasoline Engine Start
02 Fault Analysis
Generally, what affects difficult engine start mainly includes fuel system, electrical system, compression
03 pressure in cylinder, engine oil, fuel supply advance angle, ambient temperature, etc.
04 The difficulty for engine in starting may be caused by:

1. No Ignition
05 (a). Badly earthed spark plug
(b). Improper or burned-out spark plug gap
(c). Ignition coil damage
06
(d). Loose ignition coil connectors
(e). Loosening or electricity leakage of high tension wire
07 (f). Loose crankshaft position sensor harness
(g). Crankshaft position sensor damage
08 (h). Loose ECM harness
(i). ECM damage
09 2. No Starter Rotation
(a). Loosening or electricity shortage at the connections of battery terminals
10 (b). Circuit breaks
(c). Damaged starter
3. Fault of Oil Supply System
(a). Oil shortage of fuel pump
(b). Injector damage or clog
(c). Flexible fuel hose and fuel filter plug
(d). Drop or damage of vacuum hose of fuel pressure regulator
(e). ECM damage
(f). EFI harness short or break
4. Reduction in Cylinder Compression Pressure
(a). Cylinder gasket fault
(b). Improper adjustment or damage of valve clearance
(c). Wear of piston, piston ring and cylinder
Hint:
When the engine is difficult to start, it shall be considered firstly from misoperation or lack of
maintenance.
Fault Diagnosis and Troubleshooting - Fault Diagnosis and Troubleshooting of 04-3
Gasoline Engine
Troubleshooting Table
Symptom Causes Solutions

01
Sensor components: 02
(1). Poor connection between coolant (1). Reconnect relevant wires
temperature sensor and MAT sensor
03
(2). Incorrect gap between crankshaft position (2). Check and adjust the sensors
sensors in position
(3). Foreign matters and sludge on the (3). Remove foreign matters and 04
crankshaft gears sludge
(4). Poor plugging connection of the ECM (4). Check whether the 05
electronic control unit connection between the
socket and ECM electronic 06
control unit is in good
condition 07
Starting system:
08
(1). Undervoltage of battery (1). Charge the battery as
required
(2). Poor battery connection (2). Clean terminals and fasten 09
the connecting wires of
battery 10
(3). Fuse disconnection (3). Replace the fuse
(4). Faults existing in starter (4). Repair or replace the starter
(5). Faults of ignition switch (5). Repair or replace the ignition
switch。
Difficulty for
gasoline engine Fuel supply system:
in starting (1). Faults of fuel pump relay (1). Replace fuel pump relay or
check connection line
(2). Underpressure of fuel system (2). Check the fuel level in fuel
tank and the working
conditions of electric fuel
pump
(3). Leakage of injector (3). Replace the injector
Ignition system:
(1). Faults of ignition coil (1). Replace the ignition coil
(2). Anti-interference ignition cable damage (2). Replace the anti-interference
ignition cable
(3). Spark plug faults (3). Adjust the spark plug gap,
remove carbon deposit or
replace the spark plug
(4). Poor connection of ignition system (4). Connect ignition system
correctly
Mechanical part:
(1). Air leakage or ablation of valve (1). Grind or replace the valve
(2). Cylinder gasket damage (2). Replace the cylinder gasket
(3). Air leakage of intake manifold or vacuum (3). Check intake system to
tube eliminate air leakage
(4). Wear of piston, piston ring and cylinder (4). Repair or replace piston,
hole piston ring or cylinder block
Gasoline Engine
Gasoline Engine Surge

Fault Analysis
01 Gasoline engine surge presents with the symptom that its rotation speed rises and falls under
unchanged throttle opening. What affects gasoline engine surge is mainly fuel system, ignition system,
02 vacuum blockage, air leakage of intake manifold, poor valve seal, etc.
03 Gasoline engine surge may be caused by:

(a). Unstable pressure in fuel system
(b). Fuel filter plug
04
(c). Problems existing in spark plug electrode gap
(d). Vacuum blockage
05 (e). Poor valve airtightness
06 Troubleshooting Table
07 Symptom Causes Solutions
08
Fuel system:
(1). Over-thick or over-thin oil supply (1). Check whether oxygen sensor
09
and fuel pressure regulator are in
normal operation
10 (2). Unstable pressure in fuel system (2). Check whether the electric fuel
pump is in normal operation
(3). Fuel filter plug (3). Replace the fuel filter
(4). Injector clog or leakage (4). Clean or replace the injector
Ignition system:
(1). Low secondary voltage of ignition coil (1). Check the ignition circuit and
replace the ignition coil when
necessary
Gasoline engine (2). Incorrect spark plug electrode gap (2). Adjust the spark plug electrode
surge gap to 1.1mm±0.1mm。
(3). Serious ablation or large carbon (3). Remove the carbon deposit or
deposit in spark plug replace the spark plug
Others:
(1). Poor ECM electronic control unit (1). Confirm that the ECM electronic
earth connection control unit is reliably connected
(2) .Supply voltage exceeding 9~16V (2). Check whether the output voltage
of the generator is correct
(3). Clog or air leakage of vacuum tube (3). Check and clean the vacuum tube
(4). Air leakage of intake manifold (4). Check and eliminate air leakage
of intake manifold
(5). Poor valve seal (5). Grind the valve
(6). Excessive gap between valve stem (6). Replace the valve or the valve
and valve guide guide
Gasoline Engine
Gasoline Engine Knocking

Diagnosis Analysis
What affects gasoline engine knocking mainly includes cooling system, water temperature sensor, 01
gasoline, mechanical factors, etc.
02
Gasoline engine knocking may be caused by:
(a). Higher coolant temperature 03
(b). Thermostat fault
(c). Air channel or water channel blockage in radiator 04
(d). Lower octane value in gasoline
(e). Excessive carbon deposit in combustion chamber
05
06
07
Cooling system 08
(1). Higher coolant temperature (1). Add coolant and eliminate leakage
(2). Loose water pump belt (2). Tension the belt 09
(3). Air channel and water channel (3). Check and unclog the air channel
blockage through the radiator and water channel
(4). Thermostat fault (4). Replace the thermostat 10
Water temperature sensor:

(1). Output value drift of the water (1). Replace the water temperature
Gasoline engine knock temperature sensor sensor
Gasoline:
(1) Lower octane value in gasoline (1). Replace with gasoline meeting the
requirement
Mechanical factors:
(1). Higher compression ratio (1). Check the size of relevant parts
and components
(2). Excessive carbon deposit in (2). Remove the carbon deposit in the
combustion chamber combustion chamber
Gasoline Engine
Power Shortage in Operation

Fault Diagnosis
01 Engine power shortage means the power of engine does not meet the design requirements and the car
has the symptoms of “weakness”, poor exhaust gas color and so on while it is heavily loaded or is
02 climbing a steep slope. What affects engine power shortage mainly includes fuel system, intake system,
exhaust system, cooling system, compression pressure shortage in cylinder, abnormal oil temperature,
incorrect oil supply advance angle, low ambient temperature, etc.
03
Engine power shortage may be caused by:

04
(a). Improper accelerator pedal and throttle body regulation
(b). Reduction in compression pressure of cylinder
05 (c). Gasoline undersupply resulted from fuel pressure regulator damage
(d). Inadequate air intake
06 (e). Exhaust blockage
(f). Improper or damaged spark plug gap
07 (g). Injector damage or clog
(h). Throttle position sensor damage
08 (i). Fuel pressure shortage for fuel pump

10
Intake system:
(1). Air filter plug (1). Replace the air filter element
Fuel supply system:

(1). Contaminated fuel (1). Replace with gasoline meeting the
requirement
(2). Fuel pressure shortage (2). Check electric fuel pump and vacuum
line or replace the fuel pressure
regulator
Ignition system:
(1) Low secondary voltage for ignition (1). Check the ignition line and replace
coil the ignition coil when necessary
(2). Abnormal ignition control (2). Check the circuit and sensor
Power shortage
in operation
Mechanical factors:
(1). Exhaust system blockage (1). Check and eliminate exhaust system
blockage
(2). Abnormal exhaust valve opening (2). Check the exhaust opening
conditions and replace relevant parts
including valve and camshaft
Others:
(1) Poor ECM electronic control unit (1). Check harness and confirm that ECM
earthing electronic control unit is reliably
earthed
(2). Supply voltage exceeding 9~16V (2). Check whether the output voltage of
generator is normal and replace the
generator or regulator when
necessary
Gasoline Engine
Unstable Gasoline Engine Idle Speed

Fault Analysis
What affects the unstable gasoline engine idle speed mainly includes sensor, fuel system, ignition 01
system, intake system mechanical factors, etc.
02
Unstable gasoline engine idle speed may be caused by:
(a). Loose connectors of MAP and MAT sensor 03
(b). Coolant temperature sensor fault
(c). Poor contact between connectors of injector 04
(d). Injector oil supply shortage
(e). Electricity leakage of high tension wire in ignition system
05
(f). Incorrect spark plug electrode gap
(g). Carbon deposit and ablation of spark plug
(h). Air intake or leakage 06
(i). Throttle position sensor fault
07
08
09
10
Gasoline Engine
01
Sensor:
(1). Loose connectors of MAP and MAT (1). Check the connectors of each
02 sensor sensor
(2). Coolant temperature sensor fault (2). Replace the coolant sensor
03
Fuel system:
04 (1). Poor contact between the connectors (1). Recheck the connectors of the
of the injector injector
05 (2). The fuel system pressure not within (2). Check the oil pressure in fuel
300kpa system and replace relevant parts
when necessary
06 (3). Injector leakage or fuel supply (3). Check the injector and replace it
shortage when necessary
07
Ignition system:
08 (1). Secondary voltage shortage of ignition (1). Check the ignition coil and replace
coil it when necessary
09 (2). Electricity leakage of high tension wire (2). Replace the high tension wire
(3). The advance angle of idling ignition (3). Check the throttle position sensor
10 not at about 10° and MAP sensor and replace the
ECM electronic control unit when
necessary
(4). Incorrect spark plug electrode gap (4). Check and adjust the spark plug
gap
Unstable (5). Carbon deposit and ablation at spark (5). Remove the carbon deposit and
gasoline engine plug replace the spark plug when
idle speed necessary
(6). Short or high internal resistance on (6) Replace the anti-interference
anti-interference ignition cable ignition cable
Intake system:
(1). Air intake or leakage (1). Check and eliminate air intake or
leakage
(2). Idle control valve fault (2). Replace the throttle valve body
(3). Throttle position sensor fault (3). Replace the throttle position sensor
(4). Incorrect throttle opening (4). Check accelerator cable and
throttle opening
Mechanical factors:
(1). Cylinder compression pressure (1). Check and replace relevant parts
shortage
(2). Valve spring break or excessive wear (2). Replace relevant parts
of cam
Others:
(1). The voltage of power system (1). Check and maintain the generator
exceeding 9~16V and idle control and battery and replace them when
valve fault necessary
(2) Incorrect ECM electronic control unit (2). Correctly connect the earthing
earthing cable of ECM electronic control unit
and make sure the earthing is
reliable
Gasoline Engine
Excessive Pollutants at Idle Speed from Gasoline Engine

Fault Analysis
What affects the excessive pollutants at idle speed from gasoline engine mainly includes cooling system, 01
ignition system, intake system, fuel system, mechanical factors, etc.
02
The excessive pollutants from gasoline engine at idle speed may be caused by:
(a). Abnormal coolant temperature 03
(b). Spark plug fault
(c). High tension wire fault 04
(d). Abnormal ignition coil working
(e). Vacuum leakage
05
(f). Crankcase ventilation valve fault
(g). Oxygen and three-way catalytic converter damage
(h). Fuel shortage in oil tank 06
(i). Instability of electric fuel pump working
(j). Air leakage of valve 07
Troubleshooting Table 08
09
Cooling system:
(1). Abnormal coolant temperature (1). Check the cooling system and resolve 10
the faults
Ignition system:
(1). Advance angle of idling ignition not (1). Check whether each sensor is in
at about 10° normal working
(2). Spark plug fault (2). Check, clean and adjust the spark
plug gap
(3). High tension wire fault (3). Check or replace the high tension wire
(4). Abnormal ignition coil working (4). Check the ignition coil and replace it
when necessary
Intake system:
(1). Vacuum leakage (1). Check and eliminate vacuum leakage
(2). Positive crankcase ventilation valve (2). Clean or replace the crankcase
Excessive
fault ventilation fan
pollutants from
gasoline
engine at idle Post-treatment fault:
speed (1). The use of leaded gasoline or the (1). Use clean lead-free gasoline as
phosphorus and sulfur impurities in required
gasoline exceeding the standard
(2). Fire of a cylinder (2). Check oil circuit and electric circuit
and eliminate fire
(3). Oxygen sensor and three-way (3). Replace the oxygen sensor and
catalytic converter damage three-way catalytic converter
Fuel system:
(1). Fuel shortage in oil tank (1). Add fuel
(2). Instability of electric fuel pump (2). Check the electric fuel pump and its
working circuit and replace the pump when
necessary
Mechanical factors:
(1). Air leakage or jamming of valve (1). Check the coordination of valve stem
and valve guide, make sure there is no
jamming and grind the valve
Gasoline Engine
Excessive Fuel Consumption of Gasoline Engine

Fault Analysis
What affects excessive fuel consumption of gasoline engine mainly includes gasoline line, intake and
01 exhaust system, ignition system, clutch, etc.
02 Excessive fuel consumption of gasoline engine may be caused by:

(a). Oil leakage in gasoline line
03 (b). Air filter plug
(c). Air leakage in exhaust system
04 (d). Poor sensor line contact
(e). Spark plug fault
05 (f). High tension wire fault
(g). Air leakage of valve
(h). Air leakage of cylinder gasket
06
(i). Piston ring stick or break
(j). Poor clutch engaging
07
08
09
10 Gasoline line:
(1). Fuel leakage at gasoline line (1). Tighten the connectors at each part of
connections or in the line the gasoline line
Intake and exhaust system:

(1). Air filter plug (1). Check, clean and replace the air filter
element
(2). Air leakage in exhaust system (2). Eliminate the air leakage in exhaust
system
Ignition system:
Excessive
(1). Poor sensor line connection (1). Reconnect the connectors of each
fuel
sensor
consumption
(2). Fault of water temperature sensor, (2). Check sensors and replace them when
of gasoline
oxygen sensor and MAT sensor necessary
engine
(3). Spark plug fault (3). Check or replace the spark plug
(4). High tension wire fault (4). Replace the high tension wire
Clutch:
(1). Poor engaging and slipping of clutch (1) Check and adjust the clutch
Others:
(1). Air leakage of valve (1). Grind the valve
(2). Insufficient valve spring force (2). Replace the valve spring
(3). Air leakage of cylinder gasket (3). Replace the cylinder gasket
(4). Piston ring stick or break (4). Replace the piston ring
(5). Excessive wear of piston or cylinder (5). Repair or replace relevant parts
Gasoline Engine
Internal Abnormal Noise of Gasoline Engine

Fault Analysis
Abnormal noise of engine means clear sound of knock or impact is heart inside the engine or on the top 01
while the engine is in normal working. The size and frequency of the noise increase with the increase in
the rotation speed of engine. Once the noise occurs, it can hardly disappear if no remedial measures are 02
taken. Firstly, identify the noise category, impact generated by abnormal outburst or knock resulted from
abnormal movement of machine parts; then check and diagnose the noise source based on the noise 03
characteristics and noise source position in combination with the structural principle.
04
Abnormal engine noise may be caused by:
(a). Wear of bearing shell, camshaft cam and rocker arm
05
(b). Serious wear of crankshaft, connecting rod bearing shell and piston pin
(c). Piston ring damage
(d). Improper valve clearance 06
(e). Too large gap between camshaft and crankshaft thrust
07
08
09
Knock generated by loose piston pin Replace the piston pin or piston
10
Excessive wear of piston, piston ring and Overhaul or replace piston, piston
cylinder hole ring and cylinder
Replace the connecting rod
Excessive wear of connecting rod bearing shell
bearing shell
Internal Excessive wear of main bearing shell Replace the main bearing shell
abnormal noise
of gasoline Replace the crankshaft thrust
engine Excessive wear of crankshaft thrust washer
washer
Replace the camshaft thrust
Too big axial Clearance of cam
washer
Excessive carbon deposit in combustion Remove the carbon deposit in the
chamber combustion chamber
Non-conforming gasoline specifications Use the specified gasoline

04-12 Fault Diagnosis and Troubleshooting - Gasoline Engine Overheating
Gasoline Engine Overheating

Fault Analysis
01 Engine overheating will affect the overall performance of the engine, generally characterized by water
temperature gauge pointer pointing to red danger scale, radiator prone to boiling and engine bonnet
02 being opened to see the radiator with steam. Drivers and maintenance personnel shall treat it seriously
by carefully checking the causes of the fault and resolve it.
03
Engine overheating may be caused by:
04 (a). Improper spark plug gap or carbon deposit in it
(b). Loose intake manifold and clogged exhaust pipe
(c). Insufficient tension of fan belt
05
(d). Insufficient coolant or clogged water pipe
(e). Improper water pump gap or pump damage
06 (f). Insufficient engine oil
(g). Oil circuit blockage or oil pump damage
07 (h). Cylinder gasket damage
(i). Slipping of clutch
08 (j). Radiator clogged by scale deposit
09 Warning:
• If the engine overheats, never immediately stop it from operating or suddenly add coolant to
10 it, which will result in personal injury or parts damage. Instead, let off on the gas, let it run
under no load or spray a small amount of water on the surface of water tank and then stall for
check after the coolant temperature in cooling system falls.
• Do not take down the water tank cap when the engine is still heat in case of scald. Special
attention shall be paid to safety while adding coolant.
• If the causes of engine overheating cannot be found out and eliminated, you should contact
maintenance stations or plants immediately, or other parts damage may be caused.
Fault Diagnosis and Troubleshooting - Gasoline Engine Overheating 04-13

01
Insufficient coolant Add coolant as required.
02
Loose or damaged fan belt Adjust the tension of fan belt or replace it 03
Water pump fault Overhaul the water pump or replace it. 04
Thermostat fault Replace the regulator. 05
Radiator, cylinder block, cylinder head 06

Clean, repair or replace relevant parts.
Overheating and pipe line clogging or leakage
gasoline engine
Fan clutch fault Check and replace the fan clutch. 07
08
Too late ignition timing Check the ignition timing.
09
Too little or thin engine oil Add engine oil as required or replace it.
Excessive carbon deposit in the Remove the carbon deposit in the 10

combustion chamber of cylinder head combustion chamber
Blocked exhaust system Clean or replace parts of exhaust system.

Excessive Oil Consumption of Gasoline Engine

Fault Analysis
01 Excessive consumption of gasoline engine is most directly manifested in the need to frequently add oil to
gasoline engine. If so, drivers or maintenance personnel should pay attention to it and check whether the
02 engine has problems.
03 Excessive oil consumption of gasoline engine may be caused by:

(a). Engine oil leakage
(b). Poor piston and cylinder airtightness
04
(c). Poor valve airtightness
(d). Gasoline engine operating in high-speed and low-load state for a long time
05
06
07
08 Engine oil leakage:

(1). Loose oil pan drain plug (1). Tighten the oil pan drain plug.
(2). Loose oil pan fixing bolt (2). Tighten the oil pan fixing bolt.
09
(3). Damaged oil pan gasket (3). Replace the oil pan gasket.
(4). Loose front casing fixing bolt (4). Tighten the bolt or replace the
10 gasket.
(5). Damaged sealing ring for cylinder (5). Replace the sealing ring for
head cover cylinder head cover.
(6). Damaged front and rear oil seal for (6). Replace the front and rear oil
crankshaft seal for crankshaft.
(7). Loose pump fixing bolt or damaged (7). Tighten the fixing bolt or
gasket replace the gasket.
(8). Damaged fixing bolt for oil filter or (8). Tighten the fixing bolt for oil
damaged gasket filter or replace the gasket.
Poor piston and cylinder airtightness:

(1). Excessively worn or damaged oil ring (1). Replace the oil ring blade for
Excessive oil
blade piston ring.
consumption
(2). Excessively worn piston and cylinder (2). Overhaul or replace the piston
hole and cylinder block.
Poor valve airtightness:

(1). Damaged valve oil seal (1). Replace the valve oil seal.
(2). Excessively worn valve stem and (2). Replace the valve and valve
guide guide.
Crankcase ventilation system:

(1). Clogged positive crankcase (1). Check, clean and unclog the
ventilation valve positive crankcase ventilation
valve.
Increase in oil consumption:

(1). The gasoline operating engine at a (1). Avoid the gasoline engine
high speed and with low load for a operating in high-speed and
long time low-load condition for a long
time.
Low Oil Pressure of Gasoline Engine

Fault Analysis
Both over-high and over-low oil pressure of engine are of abnormal engine oil pressure, over-low oil 01
pressure more commonly seen. When the pressure is too low, the engine oil alarm blinks, indicating that
the oil pressure is low or there is no oil. With various causes for problems in engine oil pressure, drivers 02
or maintenance personnel shall treat it seriously by carefully checking the causes and resolve the faults.
03
Low oil pressure of gasoline engine may be caused by:
(a). The existence of oil leakage 04
(b). Too little or thin oil
(c). Over-high oil temperature
05
(d). Fault in the pressure limiting valve for oil pump
(e). Plugged oil filter
(f). Damaged oil pressure gauge 06
(g). Excessively worn main bearing shell and connecting rod bearing shell
07
08
09
Oil leakage Check or replace relevant parts.
10
Too little and thin oil Add or replace oil as required.
Over-high oil temperature Overhaul the cooling system.
Fault in the pressure limiting valve for Overhaul the pressure limiting valve for oil
oil pump pump.
Oil pump fault Overhaul or replace the oil pump.

Over-low oil
pressure of Oil strainer clogging and oil leakage Clean and unclog the oil strainer and tighten
gasoline on connecting line the connectors of the line.
engine
Oil strainer clogging Replace the oil strainer.
Oil pressure gauge fault Replace the oil pressure sensing plug.
Oil pressure gauge fault Replace the oil pressure gauge.

Excessive wear of main bearing,
connecting rod bearing or camshaft Replace the bearing shell or bearing.
bearing
Oil leakage on rocker-arm shaft Overhaul and tighten relevant parts.
Gasoline Engine Backfire

Fault Analysis
01 Gasoline engine backfire is mainly caused by problems in ignition system, crankshaft position sensor
and mechanical part.
02
Gasoline engine backfire may be caused by:
03 (a). Incorrect spark plug electrode gap
(b). Carbon deposit or ablation of spark plug
(c). High-voltage damp line short
04
(d). Secondary voltage shortage of ignition coil
(e). Incorrect gap between crankshaft position sensor and crankshaft pulley
05
06
07
08 Ignition system:
(1). Incorrect spark plug electrode (1). Adjust the spark plug gap to 1.1 mm ±0.1
gap mm.
09
(2). Carbon deposit or ablation of (2). Clean the carbon in spark plug or replace
spark plug the spark plug.
10 (3). Anti-interference ignition cable (3). Replace the anti-interference ignition
short cable.
(4). Secondary voltage shortage of (4). Replace the ignition coil.
Gasoline ignition coil
engine
backfire Crankshaft position sensor:
(1). Incorrect gap between crankshaft (1). Check and correct the gap.
position sensor and crankshaft
pulley
Mechanical problems:
(1). Untight valve closure (1). Check the valve.
(2). Incorrect valve timing (2). Check the valve and camshaft.
(3). Air leakage in intake and exhaust (3). Eliminate air leakage in intake and
pipe exhaust pipe.
Acceleration Lag of Gasoline Engine

Fault Analysis
Acceleration lag of gasoline engine is manifested in no speed change while pressing down on the 01
accelerator at any speed. What’s serious, the gasoline engine may come to a stall. It is mainly resulted
from problems in fuel system, ignition system, supply voltage, etc. 02
Acceleration lag of gasoline engine may be caused by: 03

(a). Too low pressure in fuel system
(b). Problems with the driving circuit of injector 04
(c). Electric fuel pump damage
(d). Fuel system clogging
05
(e). Spark plug or high-voltage cable fault
(f). Supply voltage beyond the required voltage range
06
07
08
Fuel system: 09
(1). Too low pressure in fuel system (1). Check the fuel supply pressure of
fuel pump and whether fuel filter is
10
plugged and the fuel pressure
regulator is in normal operation.
(2). Problems with the driving circuit of (2). Check the driving circuit of
injector injector.
(3). Electric fuel pump damage (3). Replace the electric fuel pump.
(4). Fuel system clogging (4). Replace the fuel filter and clean
the pipeline.
Acceleration lag
of gasoline
Ignition system:
engine
(1). Fault in the spark plug of a certain (1). Replace the spark plug or
cylinder or in the high-voltage cable high-voltage cable.
Abnormal voltage:
(1) The power system voltage beyond (1). Check the generator and battery.
9~16V
Others:
(1). Throttle jamming (1). Remove the deposited carbon and
replace the throttle valve body
when necessary.
Gasoline Engine Fuel Stop and Misfire

Fault Analysis
01 That the gasoline engine has fuel stop in acceleration and misfire is manifested in the shaking of engine
in acceleration and the sound of after-burning inside the exhaust pipe at idle and low speed. Fuel cut and
02 misfire of gasoline engine is mainly resulted from problems in fuel system, ignition system, mechanical
part, etc.
03
Fuel stop and misfire of gasoline engine may be caused by:
(a). Incorrect spark plug gap
04
(b). Carbon deposit or ablation of spark plug
(c). Incorrect fuel pressure
05 (d). Fuel filter plug
(e). Injector fault
06 (f). Problems with valve
08 Symptom Causes Solutions
09
Fuel system:
(1). Incorrect fuel system pressure (1). Check whether the electric fuel
10 pump and fuel pressure regulator
are in normal operation.
(2). Fuel filter plug (2). Replace the fuel filter.
(3). Injector fault (3). Replace the injector.
Ignition system:
(1). Incorrect spark plug gap (1). Replace the spark plug or
Fuel stop and high-voltage cable.
misfire of (2). Carbon deposit or ablation of spark (2). Replace the fuel filter.
gasoline plug
engine (3). Anti-interference ignition cable short (3). Replace the injector.
Mechanical part:
(1). Incorrect valve timing (1). Check the valve timing.
(2). Untight valve closure (2). Grind the valve.
(3). Valve spring break or fault (3). Replace the valve spring.
(4). Camshaft fault (4). Replace the camshaft.
Others:
(1). Electromagnetic interference (1). Check whether the high-voltage
cable has electricity leakage.
Fault Diagnosis and Troubleshooting - Fundamentals of Fault Diagnosis of Engine 04-19
EFI System
Fundamentals of Fault Diagnosis of Engine EFI System

Diagnosis Instructions
1. The EFI system of gasoline engine is relatively complicated and its fault diagnosis demands the 01
grasp of the principle and structure of the system, overhaul procedures and the usage of overhaul
instruments. To resolve a gasoline engine fault that may involve EFI system, whether the fault is 02
related to EFI system shall be determined firstly. If the engine is found to have faults but the fault
indicator is not on, this fault is usually irrelevant to EFI system. 03
2. The faults shall be diagnosed and checked with the help of some instruments and meters, circuit
test lamp, multimeter, special fault diagnostic instrument and so on for the commonly used.
04
To diagnose the faults in the EFI system of gasoline engine, the following areas of knowledge must be 05
mastered:
(a). General situations and fundamental principles of EFI system
(b). How sensors, ECM electronic control unit and actuator operate and their performance parameters 06
(c). Symbols of interface terminals of ECM electronic control unit and sensors
07
Cautions 08
1. Do not open the cover of ECM electronic control unit, which cannot be maintained even if breaks
down. This move may damage the unit if it is in good condition. 09
2. Pay attention to prevent water from spraying onto the wires of gasoline engine and sensors to cause
short while using and repairing the engine. 10
3. Wire and wire interface mainly have the faults of break, short and ground.
Break is mainly caused by wire break, poor connection, etc. The break of wire usually takes place at
the connections, so wire connections shall be checked first in order to resolve the fault. Poor contact
may give rise to the oxidation of terminals and the entry of foreign matter.
Short is mainly resulted from electrical wiring, body ground or internal short of switch. While
checking whether there is short between electrical wiring and body, attention should paid to
checking whether there is wire stuck in the car or whether there is friction with body and frame to
cause damage to the insulation layer and thereby cause electricity leakage.
4. In checking the circuit break, disconnect ECM electronic control unit and corresponding sensor
interfaces first and then measure the resistance between connecting terminals so as to determine
whether there is break or poor contact.
5. In checking whether there is wire ground and short, disconnect the interfaces at both ends of the
circuit and then measure the resistance between interface terminal and body ground. If the
resistance is above 2Ω, it is up to standard.
6. No matter whether the gasoline engine is in operation or not, while the ignition switch is on, it is
prohibited to deenergize any 12V electric working installation, such as any cable of the battery, idle
control valve, injector, electric fuel pump, wires of ignition system, circuit of ECM electronic unit,
air-conditioning circuit and so on.
7. In checking sensors and ECM electronic control unit, digital multimeter shall be used, or the sensors
and ECM electronic unit will get damaged.
8. When the inspection lamp for gasoline engine gets on during the operation of the engine, make sure
to ascertain the causes as soon as possible to resolve it.
9. Abnormal oil consumption, if any, shall be resolved as soon as possible, because some matters in
the oil will damage the oxygen sensor and three-way catalytic converter.
10. When a certain cylinder is found to catch fire, the car shall be immediately stopped for check and
resolution, because the unburned mixture will burn in exhaust, which will damage the oxygen
sensor and three-way catalytic converter very soon. If the ignition fault cannot be resolved for a
short while, it is advisable to disconnect the injector plug of the cylinder on fire.
11. The faults of engine are often not caused by electronic fuel system, so the working conditions of
other systems should be checked first in fault diagnosis:
(a). Power supply: battery and fuse
(b). Body grounding
04-20 Fault Diagnosis and Troubleshooting - Fundamentals of Fault Diagnosis of Engine
EFI System
(c). Oil supply: fuel leakage, fuel filter and fuel pump
(d). Ignition system: spark plug, high-voltage cable, distributor, power transistor ( igniter) and
ignition coil
01 (e). Intake system: vacuum leakage
(f). Exhaust pollution control system: PCV system, EGR system and purification control system
02 (g). Others: ignition timing and idling
12. The fault is mostly caused by the poor contact between the connectors of the wiring, so the following
points shall be paid special attention to in checking the opposite components:
03 (a). Check whether terminals are complete.
(b). Check whether the connectors are completely inserted and locked in.
04 (c). Observe whether signals have changes while tapping or twisting the connectors.
13. Fault diagnosis shall be adequately performed to other causes before replacing ECU which belongs
05 to product with high quality and high price.
06
07
08
09
10
Fault Diagnosis and Troubleshooting - Fault Diagnosis and Troubleshooting of EFI 04-21
System of Gasoline Engine
Fault Diagnosis and Troubleshooting of EFI System of

Gasoline Engine
01
Working Principles of Diagnosis
The diagnosis is performed according to three principles: 02
(a). The normal voltage of input and output signal of electronic control unit (ECU) changes within a
certain range. When signals beyond the specified voltage range appear in a certain circuit, the
03
diagnostic system determines signals in this circuit have faults. For example, when water
temperature sensor works in normal condition, the output voltage shall vary from 0.1V to 4.8V; if the
output voltage is less than 0.1V (equal to water temperature above 139℃) and more than 4.8V 04
(equal to water temperature below -50℃), it is diagnosed that the water temperature sensor is
abnormal. 05
(b). In the determination of “abnormal” signal, if the abnormal signal occurs only once by accident, the
diagnostic system does not judge it as the sign of faults. Only when abnormal signals last for a 06
period of time can fault codes be stored in the memory.
(c). The occurrence of a fault is not only related to sensors and actuators but also to the whole circuit in 07
which the fault occurs. Therefore, in order to check the causes of the fault, apart from sensors and
actuators, wires, plugs, electronic control unit and other components related to this signal circuit
shall also be checked. For instance, even if the water temperature sensor is normal in itself, the 08
diagnostic system will still indicate that there are faults in water temperature signals if the circuit is
open. 09
10
04-22 Fault Diagnosis and Troubleshooting - Fault Diagnosis and Troubleshooting of EFI
Fault Diagnosis Procedures
01
Collect customer
02 information
03
Check the conditions of
04 faults
05 Repetitive occurrence Non-repetitive occurrence
06
Read fault codes Read fault codes

07
08
09
No display of fault
10 Display of fault codes Display of fault codes codes
Failure to display
normal codes
Refer to Check List of Record fault codes and

Fault Symptoms delete their memory
Recheck the conditions

of faults
Abnormal
Read detected fault

codes
Display of fault codes No display of fault codes
Refer to Fault Code Intermittent

Table faults
Fault Code Reading

1. Cautions for Fault Code Reading:
(a). If the too low battery voltage causes the failure of fault codes to be outputted, the battery voltage
01
must be checked first before the check.
(b). When the battery is cut off or the engine ECU joints are cut off, the detection code memory will be
cleared. 02
(c). Before the KT600 joints are connected and removed, the ignition switch must be made sure to be in
off-position. 03
2. Fault Code Reading Procedures: 04

(a). Connect KT600 to fault diagnosis joints (16 pins) and read fault check codes.
(b). Refer to Fault Code Table, check fault items and resolve them. 05
(c). Turn off the ignition switch and then turn on.
(d). Use KT600 to clear fault check codes.
(e). Remove KT600. 06
(f). Re-start the engine for test so as to make sure problems have been eliminated.
07
08
09
10
Fault Code Table

Corresponding Fault codes
Fault description Type Corresponding CAL parameters
components (H/D)
01
Intake pressure/throttle
P0106 262 position sensor rational E KsDGDM_MAP_TPS_Rationality
02
fault
MAP sensor Low voltage or break of
03 P0107 263 A KsDGDM_MAP_ShortLow
MAP sensor circuit
04 High voltage of MAP
P0108 264 A KsDGDM_MAP_ShortHigh
sensor circuit
05 P0112 274 Low voltage of MAT sensor E KsDGDM_IAT_ShortLow
MAT sensor
06 High voltage of MAT
P0113 275 E KsDGDM_IAT_ShortHigh
sensor
07 Low voltage of coolant
Coolant P0117 279 A KsDGDM_CoolantShortLow
temperature sensor circuit
08 temperature
sensor High voltage of coolant
P0118 280 A KsDGDM_CoolantShortHigh
temperature sensor circuit
09
Low voltage of throttle
Throttle P0122 290 A KsDGDM_TPS_ShortLow
position sensor
10 position
sensor High voltage of throttle
P0123 291 A KsDGDM_TPS_ShortHigh
position sensor
P0171 369 Too thin fuel system E KsDGDM_Fueltrim_B1_Lean

Fuel system
P0172 370 Too thick fuel system E KsDGDM_Fueltrim_B1_Rich
Misfire P0300 768 Misfire B\A KsDGDM_Misfire

Interfering signals in
P0336 822 crankshaft position sensor E KsDGDM_CrankNoisySingal
circuit
58X sensor No signals in crankshaft
P0337 823 A KsDGDM_CrankNoSignal
position sensor
No learning of 58 gear
P1336 4918 A KsDGDM_ToothErrorCorrection
errors
Corresponding Fault codes Corresponding CAL

Fault description Type
components (H/D) parameters
KsDGDM_FuelLevelCo 01
P0461 1121 Rational fault of fuel position sensor C
nsumption
Line-to-ground short circuit of fuel KsDGDM_FuelLevelSh 02
P0462 1122 C
Fuel position position sensor ortLo
sensor Fuel position sensor short circuit on KsDGDM_FuelLevelSh 03
P0463 1123 C
the power ortHi
KsDGDM_FuelLevelNo 04
P0464 1124 No signals of fuel position sensor E
isySignal
Three-way 05
Catalytic efficiency lower than the KsDGDM_CatalystBan
catalytic P0420 1056 A
limit k1
converter 06
P0562 1378 Too low system voltage C KsDGDM_SysVoltLow
07
System voltage
P0563 1379 Too high system voltage C KsDGDM_SysVoltHigh 08
Air-conditioning clutch line output KsDGDM_AC_Clutch_
A/C clutch P1545 5445 C 09
fault OutputFault
KsDGDM_Inj_Cylinder
P0201 513 Fault of nozzle A A
_1_Fault 10
KsDGDM_Inj_Cylinder
P0202 514 Fault of nozzle B A
_2_Fault
Injection nozzle
KsDGDM_Inj_Cylinder
P0203 515 Fault of nozzle C A
_3_Fault
KsDGDM_Inj_Cylinder
P0204 516 Fault of nozzle D A
_4_Fault
Idle speed control – Too low KsDGDM_IdleRPM_To
P0506 1286 E
Idle speed rotational speed fault oLow
control system Idle speed control – Too high KsDGDM_IdleRPM_To
P0507 1287 E
rotational speed fault oHigh
Vehicle speed KsDGDM_VSS_NoSig
P0502 1282 No signals of vehicle speed sensor E
sensor VSS nal

KsDGDM_RRID_RR_S
01 P1390 5008
OURCE
02 Rational fault of acceleration KsDGDM_RRID_G_Se
P1391 5009 C
Acceleration sensor nRationality
03 sensor G Acceleration sensor short circuit to KsDGDM_RRID_G_Se
P1392 5010 C
ground nShortLo
04 Acceleration sensor short circuit on KsDGDM_RRID_G_Se
P1393 5011 C
the power nShortHi
05 Front oxygen sensor short circuit to KsDGDM_O2_11_Shor
P0131 305 A
ground tLow
06 Front oxygen sensor short circuit on KsDGDM_O2_11_Shor
P0132 306 A
the power tHigh
07
Feedback fault of front oxygen KsDGDM_O2_11_Res
P0133 307 E
sensor ponse
08
Front oxygen KsDGDM_O2_11_Ope
P0134 308 Open circuit of front oxygen sensor A
sensor n
09
Heating faults of front oxygen KsDGDM_O2_11_Heat
P0135 309 A
10 sensor erFault
Too high concentration given by the KsDGDM_O2_11_Rich
P1167 4455 E
front oxygen sensor at deceleration DFCO
Too low concentration given by the KsDGDM_O2_11_Lea
P1171 4465 E
front oxygen sensor at acceleration nPE
Rear oxygen sensor short circuit to KsDGDM_O2_12_Shor
P0137 311 E
ground tLow
Rear oxygen sensor short circuit on KsDGDM_O2_12_Shor
P0138 312 E
Rear oxygen the power tHigh
sensor KsDGDM_O2_12_Shor
P0140 320 Open circuit of rear oxygen sensor E
tOpen
KsDGDM_O2_12_Heat
P0141 321 Heating fault of rear oxygen sensor E
erFault

KsDGDM_KnockSenso 01
P0327 807 Knock sensor fault C
r
Knock sensor
KsDGDM_KnockSyste 02
P0325 805 Knock system fault C
m
KsDGDM_FuelPump_ 03
P0230 560 Fuel pump relay fault C
OutputFault
KsDGDM_MIL_Output 04
P0650 1616 Malfunction indicator lamp faults C
Fault
EMS hardware 05
KsDGDM_FANA_Outp
P0480 1152 Fan 1 fault C
utFault
06
KsDGDM_Purge_Solen
P0443 1091 Valve EGR fault E
oid_Ouput
07
P0645 1605
08
KsDGDM_RLCO_Outp
P2100 8448
utFault 09
Front air-conditioning evaporator KsDGDM_FrontACEVT
P2000 8192
temperature sensor faults Fault 10
Rear air-conditioning evaporator KsDGDM_RearACEVT
P2001 8193
temperature sensor fault Fault
Fault of AT gear judgment signal KsDGDM_PRNDL_Fau
P0705 1797
transferred through CAN lt
KsDGDM_Mainrelay_O
P0685 1669 Main relay output fault
utputFault
KsDGDM_FILEROM_C
P0601 1537 Fault of Flash Checksum
HECKSUM
KsDGDM_FANB_Outp
P0481 1153 Fault of fan 2
utFault
KsDGDM_FANC_Outp
P0482 1154 Fault of fan 3
utFault
KsDGDM_FANPWM_O
P0483 1155 Fault of PWM fan
utputFault

CAN communication failure of drive KsDGDM_CAN_TCM_
01 P0615 1557
system COMMUNICATION
02 Short high distortion of AC pressure KsDGDM_AC_PRESS
P0532 1330
sensor HORTHIGH
03 P0533 1331
Short low distortion of AC pressure KsDGDM_AC_PRESS
sensor HORTLOW
04 KsDGDM_COOLANTS
P1114 4372
HORTLOWINT
05 KsDGDM_COOLANTS
P1115 4373
HORTHIGHINT
06 KsDGDM_COOLANTS
P0115 277
TUCK
07
KsDGDM_COOLCL_T
P0125 293
EMP
08
KsDGDM_COOLHIGH
P0217 535
_TEMP
09
KsDGDM_CAMRATIO
P0341 833
10 NALITY
KsDGDM_COOLHIGH
P0342 834
_TEMP
KsDGDM_MAPCID_Fa
P0343 835 Fault of CIS E
ult
KsDGDM_EST_CIRCU
P0351 849 Fault of ignition coil 1
IT_1
KsDGDM_EST_CIRCU
IT_2
KsDGDM_EST_CIRCU
IT_3
KsDGDM_EST_CIRCU
IT_4

KsDGDM_IAT_SHORT
P1111 4639 01
HIGHINT
KsDGDM_IAT_SHORT
P1112 4370
LOWINT 02
KsDGDM_MAP_SHOR
P1106 4358
THIGHINT 03
KsDGDM_MAP_SHOR
P1107 4359
TLOWINT 04
KsDGDM_MISFIRE_L
P0313 787
OWFUELLEVEL
05
Description of fault types:
Type A: Light the fault lamp immediately when the fault code appears for the first time; 06
Type B: Light the fault lamp when the fault code appears for the consecutively second time; for misfire
fault, misfire with emissions damage falls type B and misfire with catalytic converter falls type A; 07
Type C: Record the fault code when the fault occurs but not light the fault indicator lamp;
Type E: Light the fault lamp when the fault code appears for the consecutively third time. 08
09
10
Definition of MT20U Pin

1. Distribution Map of Pins
01
02
03
04
05
06
07
08
2. Definitions of Pins
09
No. Definitions No. Definitions No. Definitions
10
Power supply of ignition Front evaporator temperature
1 26 51
switch signal
2 27 Intake temperature 52 Drive of ignition coil B
3 Vehicle speed signal 28 Low 58 tooth signal 53 Idle air control A, low
No.2 5V power supply, Maintenance services lamp

4 29 54 Idle air control A, high
positive (SVS)
No.1 5V power supply, Diagnosis request (only

5 30 55 Nozzle signal of cylinder 1
negative limited to MT20U)
Low oxygen sensor signal
6 (shared by both front and rear 31 Fault diagnosis lamp (OBD) 56 Nozzle signal of cylinder 3
oxygen sensor)
7 Security password (optional) 32 Drive of ignition coil A 57
Low and effective

8 air-conditioning request 33 Idle air control B, high 58 Main relay control
(optional)
Low and effective electrical Low and effective electrical
9 34 Idle air control B, low 59
load signal load signal (optional)
Camshaft position signal

10 35 Acceleration signal 60 Security request (optional)
(optional)
KW2000 serial data Power steering signal

11 36 61 Front oxygen sensor heating
communications (optional)
High front oxygen sensor

12 High 58 tooth signal 37 62
signal
Linear exhaust-gas
High rear oxygen sensor Canister solenoid valve
13 recirculation feedback 38 63
signal control
(optional)
No. Definitions No. Definitions No. Definitions
Effective air-conditioning 01
14 Low CAN (optional) 39 64 Rear oxygen sensor heating
request
15 High CAN (optional) 40 65

Linear exhaust-gas 02
recirculation drive (optional)
16
Drive of ignition coil A
41 Neutral gear signal (optional) 66
Linear exhaust-gas 03
(optional) recirculation drive (optional)
04
17 Battery power (12VDC+) 42 Intake pressure 67 Low-speed fan control
Posterior circulation cut of 05

18 Battery power (12VDC+) 43 Coolant temperature signal 68
cooling system (optional)
06
Rear evaporator temperature
19 44 69 Knock signal
signal (optional)
07
No.1 5V power supply,
20 45 Rotational speed output 70 Nozzle signal of cylinder 2
negative
08
Low and effective
No.2 5V power supply,
21 46 air-conditioning compressor 71 Nozzle signal of cylinder 4
positive
approval 09
Drive of ignition coil C
22 47 Fuel pump relay control 72
(optional) 10
23 Oil level signal (optional) 48 73 System grounding
24 Throttle position signal 49
25 50 High-speed fan control

3. Joint Definition of Fault Diagnosis
01
02
03
04
05
06
07
08
1 Diagnosis request 9 Empty
09
2 Empty 10 Empty
10
3 Empty 11 Empty
4 Earth wire 12 Empty
5 Earth wire 13 Empty
6 Empty 14 Empty
7 Communication 15 Empty
8 Empty 16 +12V
4. Connection Diagram of Seal-made Data Download Cables
01
02
03
04
05
06
07
08
09
10
Inspection and Troubleshooting of Fault Symptoms

Symptom 1: KT600 fails to communicate with all systems.
1. Fault Problems and Analysis
01
KT600’s failure to communicate with all systems Possible reasons
02
Poor power supply system of self-diagnostic circuit (a). Poor joint contact
(including poor ground) (b). Fault of harness
03
2. Troubleshooting Steps
04
05
Measure the fault diagnosis joint
06 • The voltage between terminal 16
and ground
Normal: Battery voltage
07
Normal
08 Abnormal
09
Measure the following terminals of fault Check the harness between
diagnosis joint:
10 • Continuity between terminal 4 and ground
these two terminals and ground
and replace it when necessary
• Continuity between terminal 5 and ground
Normal: Continual
Normal Abnormal Normal Abnormal
Check the harness between Repair

Replace KT600 these two terminals and ground Check fault symptoms
and replace it when necessary
Abnormal
Check the harness between the

power supply system and the
self-diagnostic circuit and
replace it when necessary
Symptom 2: KT600 fails to communicate with engine ECU.

1. Fault Problem Analysis
KT600’s failure to connect with engine ECU Possible reasons
01
This may be caused by any of the following:
(a). The power fails to be supplied to the engine ECU. (a). Poor power supply circuit of engine ECU 02
(b). Fault of engine ECU (b). Fault of engine ECU
(c). Poor circuit connection between engine ECU and (c). Circuit break between engine ECU and KT600
KT600 03
2. Troubleshooting Steps 04
05
Check the harness continuity between the fault
diagnosis joint and the engine ECU
• The continuity between terminal 1 and terminal 30 06
of ECU
• The continuity between terminal 7 and terminal 11
of ECU
Normal: continual 07
08
09
Repair
10
Check the harness between
engine ECU and ground
Check the power supply Repair

system and ignition switch
system
Symptom 3: When the ignition switch is ON, the engine warning lamp will not be on at once.
When the ignition switch is shifted to ON, the engine
Possible reasons
01 warning lamp will not be on at once.
When the ignition switch is shifted to ON, the engine (a). The burnout of bulb
02 warning lamp will be on at once and then automatically off (b). Fault of engine warning lamp circuit
after 5 seconds. (c). Engine ECU fault
If the engine warning lamp is not on, it may be caused by
03 faults in the right column.
04 2. Troubleshooting Steps
05 Check the harness between engine

Use KT60 to check the power Abnormal
ECU power supply system and
supply voltage of engine ECU
06 ground
07 Normal
08
Measure the ECU terminal 31 Normal
• Connect terminal 31 to ground
Check the ECU terminal 31
09 Normal: The engine warning lamp is on.
10
Abnormal Normal
Abnormal
Check whether the bulb is Abnormal
Replace Check the fault symptoms
burnt out
Normal Abnormal
Repair
Check the joint of engine Abnormal

warning lamp on the Repair Replace ECU
instrument panel
Normal
Abnormal Check the harness between the

instrument panel and the ECU
Check the fault symptoms terminal 32 and replace it when
necessary
Symptom 4: The engine warning lamp fails to go out.

The engine warning lamp does not go out. Possible reasons
01
(a). Harness short between the engine warning lamp and
It may be caused by the fault of a sensor or actuator
detected by the engine ECU or the right column fault.
ECU 02
(b). Fault of engine ECU
03
04
Use KT600 to read fault codes Yes 05

to check whether there are Refer to Fault Code Table
fault codes
06
07
No
08
09
Check the harness and joint Abnormal
between the engine warning Repair
lamp and the engine ECU 10
Abnormal
Replace the engine ECU

Symptom 5: The starter rotates without combustion in the cylinder, but the engine fails to start.
The starter rotates, but the engine fails to start. Possible reasons
01
This may be caused by poor spark plug or no fuel supply to (a). Fault of ignition system
02 the combustion chamber. (b). Fault of fuel supply system
(c). Fault of injection nozzle
(d). Fault of engine ECU
03 (e). Fault of intake system leakage
04
05
06
07
08
09
10
01
Abnormal
Check the battery voltage
Check the battery
at start 02
Normal
03
Use KT600 to diagnose Yes Check the electric fuel Check the fuel injector and
Refer to Fault Code Table
whether there are fault
codes
pump and its control circuit its harness and replace 04
then when necessary
No No No 05
Normal Check whether the No Check whether the electric Yes Check whether the engine
Check the ignition spark
engine is started fuel pump works is started 06
Yes With action
07
Abnormal Check whether the Clogged Measure the fuel
engine is started Replace
pressure 08
Check the ignition coil, spark 09

plug, high tension wire, spark Normal
plug cable and distributor of the
ignition system Normal Abnormal 10
Check whether there is Yes

leakage in intake system Repair
Check cylinder pressure Check the oil pressure

No regulator, electric fuel
pump and fuel filter
Check the spark plug gap Abnormal

Replace
Normal
Abnormal Check the oil pressure

Measure the fuel
pressure regulator, electric fuel
pump and fuel filter
Normal
Detect the air flow sensor Abnormal

and water temperature Replace
sensor
Normal
Check whether the fuel No Check the fuel injector and

injector operates its harness and replace
then when necessary
Normal
Check the cylinder

pressure
Symptom 6: The engine can be started but flames out at once.

The engine can be started but flames out at once. Possible reasons
01
This may be caused by the too weak spark of spark plug or (a). Fault of ignition system
02 the incorrect mixture ratio. (b). Fault of injector
(c). Too low compression pressure in cylinder
(d). Engine ECU fault
03
04
05
Check the battery voltage at start Abnormal
Check the battery
Normal: Above 8V
06
No
07 Use KT600 to check whether there

Yes
are fault codes
08 No
Check whether the injector

09 operation can be heard while Abnormal
Check the fuel injector
starting the generator (contact the
injector casing with a screw driver)
10 Normal
Observe whether the engine is easier Yes Abnormal

Check the operation sound of Check the stepping motor system
to start after slightly pushing the
stepping motor
accelerator pedal down
Normal
No
Clean the throttle body
Check the ignition timing at the start

of generator
Normal
Check the following items:

1. Ignition coil, spark plug and high
tension wire
2. Whether the fuel injector is clogged
2. Compression pressure
3. Whether the fuel line is clogged
Symptom 7: The starter is started after a long time (the start method is incorrect).
The starter is started after a long time (the start method is
Possible reasons
incorrect). 01
This may be caused by too weak spark of the spark plug (a). Fault of ignition system
resulting in difficult ignition, improper air/fuel ration or too (b). Fault of fuel injector 02
low compression pressure at start. (c). Too low compression pressure
03
04
Abnormal 05
Check the battery voltage at start Check the battery
Normal: Above 8V
06
Normal 07
Use KT600 to diagnose whether there

08
Yes
are fault codes Refer to Fault Code Table
09
No 10
Check whether the injector operation

Abnormal
can be heard while starting the
generator (contact the injector casing
with a screw driver)
Normal
Check the ignition timing at the start of

generator
Normal

1. Ignition coil, spark plug and high tension
wire
2. Whether the fuel injector is clogged
Symptom 8: The idle speed is unstable (up and down).

The idle speed is unstable (up and down). Possible reasons
01
This may be caused by poor ignition system, air/fuel ratio (a). Fault of ignition system
02 and stepping motor or too low compression pressure. (b). Fault of idle air/fuel ration control system
(c). Too low compression pressure
(d). Fault of air into the intake system
03
04
05
Use KT600 to diagnose whether Yes
there are fault codes Refer to Fault Code Table
06
No
07
Check the operation sound of Abnormal Check the control circuit and
08 stepping motor the stepping motor and replace
the stepping motor when
09 Normal
10 Detect the water temperature sensor Abnormal

and air flow sensor Replace
Normal
Check the oxygen sensor Abnormal

Replace
Normal
Check the oxygen sensor Abnormal

Replace
1. Check ignition coil, spark plug and high

Normal tension wire
2. Check the purification control system
3. Check the ignition timing
4. Check the compression pressure
5. Remove, clean or replace the fuel injector
Symptom 9: The idle speed is too high or too low (beyond the specified value).
The idle speed is too high or too low (beyond the specified
Possible reasons
value). 01
Too high idle speed may be caused by excessive air intake (a). Fault of stepping motor
at idle. (b). Fault of throttle body 02
Too low idle speed may be caused by inadequate air intake
at idle.
03
04
Yes
05
Use KT600 to diagnose whether there
are fault codes
06
No
Check the operation sound of Abnormal 07

Check the stepping motor
stepping motor
08
Normal
Check the idle position switch

Abnormal
Replace
09
10
Normal
Abnormal
Check the water temperature sensor Replace
Normal
Abnormal Check the air conditioning switch and

Check the air conditioning switch
the air-conditioning compressor relay
Normal
Adjust the basic idle speed
Normal
Abnormal
Check fault symptoms Clean the throttle body
Symptom 10: The engine will have flameout while cold (at idle).
The engine will have flameout while cold at idle. Possible reasons
01
This may be caused by incorrect air/fuel ratio in the mixture (a). Fault of stepping motor
02 in cold engine or insufficient air intake. (b). Fault of throttle body
(c). Fault of fuel injector
(d). Fault of ignition system
03
04
05
06
07
08
09
10
01
Use KT600 to diagnose whether Yes Refer to Fault Code Table
there are fault codes 02
No
03
Check whether the engine will have Yes
flameout as soon as the accelerator Clean the throttle body
pedal is released 04
No
Whether the idle speed is stable No 05

after the engine warms up Refer to the check procedures 8
Yes 06
Check the operation sound of the Abnormal

stepping motor Check the stepping motor 07
Normal 08
Abnormal
Check the operation sound of the Check the fuel injector
fuel injector 09
Normal
Abnormal
10
Check the idle position switch Replace
Normal
Check the water temperature Abnormal

sensor Replace
Normal
Check the fuel pressure
Normal
Check the ignition timing
Normal

tension wire
3. Oil viscosity
Symptom 11: The engine will have flameout while warming up (at idle).
The engine will have flameout while warming up at idle. Possible reasons
01
This may be caused by poor ignition system, air/fuel ration, (a). Fault of air/fuel ration control system
02 stepping motor or compression pressure. If the engine has (b). Fault of harness joint contact
sudden flameout, it may be caused by poor contact of (c). Fault of air into the intake system
harness joint. (d). Fault of ignition system
03
04
05
06
07
08
09
10
01
02
Use KT600 to diagnose whether Yes
there are fault codes
03
No

Check the stepping motor 04
stepping motor
Normal 05
fuel injector Check the fuel injector 06
Normal
07
Check whether the engine will has Yes
flameout as soon as the accelerator Clean the throttle body
pedal is released 08
No
Whether the engine is still prone to

No Conduct intermittent fault simulation test and check whether the following 09
flameout signals have changes:
1. Crank angle sensor signal
Yes 2. Air flow sensor signal 10
3. Injector drive signal
4. Ignition signal of primary coil and secondary coil
Check the engine flameout in
preheating and at idle 5. Fuel pump drive signal
6. Power supply for the engine ECU
Normal
Normal

tension wire
2. Whether the injector is clogged
Symptom 12: The engine has flameout at start.

The engine will has flameout at start. Possible reasons
01
This may be caused by ignition failure from too weak spark (a). Fault of air into the intake system
02 plug or incorrect air/fuel ratio at the release of accelerator (b). Fault of ignition system
pedal.
04
05
06 Use KT600 to read fault codes Yes

to check whether there are fault Refer to the fault code table
codes
07
08
No
09
10 Check the following items:

1. Ignition coil, spark plug and high tension wire
2. Whether there is air into the intake system
3. Whether the intake manifold gasket is
damaged
4. Whether the vacuum hose is damaged or
gets loose
5. Poor functions of PCV valve
6. Intake hose damage
Symptom 13: The engine has flameout at deceleration.

The engine will have flameout at deceleration. Possible reasons
01
This may be caused by insufficient air intake in the engine (a). Poor stepping motor system
resulted from the fault of stepping motor system. 02
04
05
Yes
06
Use KT600 to diagnose whether Refer to Fault Code Table
there are fault codes
07
No
Check the idle position switch

Abnormal 08
Replace
09
Normal
Check the throttle position sensor

Abnormal
Replace
10
Normal
Check the steps of stepping motor

Yes
At deceleration (The engine speed is lower than Check the vehicle speed sensor
1000rmp.)
Whether the steps of stepping motor decrease
by 0-2 steps
No

tension wire
2. Clean the throttle body
Symptom 14: Acceleration Slowness or Maladjustment

Acceleration slowness or maladjustment Possible reasons
01
This may be caused by poor ignition system, air/fuel ratio or (a). Fault of ignition system
02 compression pressure. (b). Fault of air/fuel control system
(c). Fault of fuel supply system
(d). Too low compression pressure
03
04
05 Use KT600 to read fault codes to check Yes

whether there are fault codes
06
No
07
Check the operation sound of fuel Abnormal
injector Check the fuel injector
08
Normal
09
Check the operation sound of fuel
10 injector
Normal
Normal

1. Ignition coil, spark plug and high tension wire
3. Whether there are fuel filter or line clog and air leak in
intake system
Symptom 15: There is a sensation of vibration in acceleration.

There is a sensation of vibration in acceleration. Possible reasons
01
This may be caused by poor stepping motor system. (a). Fault of stepping motor system 02
04
05
06
07
Use KT600 to read fault codes to check Yes
whether there are fault codes
08
No
09
tension wire 10
2. Whether there is electricity leakage
Symptom 16: There is a sensation of vibration in deceleration.

There is a sensation of vibration in deceleration. Possible reasons
01
02 This may be caused by poor stepping motor system. (a). Fault of stepping motor system
04
05 whether there are fault codes
06 No
Abnormal
07 Check the operation sound of stepping
motor Maintain
08 Normal
09 Check the throttle position sensor

Abnormal
Replace
10
Normal
Abnormal
Check the idle position switch Replace
Normal
Clean the throttle body

Symptom 17: Poor Acceleration

Poor acceleration Possible reasons
01
This may be caused by the fault of ignition system, (a). Fault of ignition system
abnormal air/fuel ratio or inadequate compression (b). Fault of air/fuel ration control system 02
pressure. (c). Fault of fuel supply system
(d). Too low compression pressure
(e). Exhaust system clog 03
05
Yes
Use KT600 to read fault codes to check Refer to Fault Code Table
whether there are fault codes 06
No
07
injector Check the fuel injector 08
Normal 09
Check the ignition timing 10
Normal
Normal

1. Ignition coil, spark plug and high tension
wire
3. Intake hose damage
4. Air filter clog
Symptom 18: Shake

Engine shake means when the vehicle runs at a constant
Possible reasons
01 speed it will shake back and forth when the speed changes.
This may be caused by the fault of ignition system and (a). Fault of ignition system
02 abnormal air/fuel ratio (b). Fault of air/fuel ratio control system
04
05 whether there are fault codes
No
06

07 injector
08 Normal
09 Check the ignition timing
10
Normal
Normal
Check the ignition coil, spark plug and

high tension wire
Symptom 19: Knock

Engine knock means the engine makes a sharp knocking
Possible reasons
sound when the vehicle is running. 01
This may be caused by the improper use of heat rating of (a). Incorrect heat rating of the spark plug
the spark plug. 02
(a). The model of spark plug 04
(b). Fuel type or quality
05
Symptom 20: Post-ignition
1. Fault Problem Analysis 06
Engine post-ignition means the engine still keeps
operating when the ignition switch is shifted to OFF Possible reasons
07
in the engine operation.
This may be caused by oil leakage of the injection (a). Oil leakage of the injection nozzle 08
nozzle.
09
(a). Check whether the injection nozzle has oil leakage
10
Symptom 21: The CO and HC concentration is too high at idle.

The CO and HC concentration is too high at idle. Possible reasons
01
02 This may be caused by abnormal air/fuel ratio. (a). Fault of air/fuel ration control system.
04
Use KT600 to diagnose whether there Yes
are fault codes Refer to Fault Code Table
05
No
06
07
Normal
08 Detect the water temperature sensor

Abnormal
Replace
09
Normal
10 Detect the MAT sensor

Abnormal
Replace
Normal
Abnormal
Detect the barometric pressure sensor Replace
Normal
Check the fuel pump
Normal

1. Whether the fuel injector operates
2. Whether the injector has oil leakage
3. Ignition coil and spark plug
4. Cylinder compression pressure
5. Purification control system
6. Positive crankcase ventilation system
(PCV valve)
Symptom 22: Power Supply System and Ignition Switch IG

Power supply system and ignition switch IG Possible reasons
01
When the signal ON of ignition switch is transmitted to the (a). Fault of ignition system
engine ECU, ECU will control the relay ON, which makes (b). Fault of control relay 02
the power of battery be supplied to the engine ECU, the (c). Poor harness joint contact, harness break or short
fuel injector and the air flow sensor. (d). Loose ground cable of the engine ECU
(e). Fault of engine ECU 03
05
06
07
Abnormal
Check the control relay
Replace 08
Normal 09
Abnormal
Check the control relay joint harness Replace 10
Normal
Check the power supply and ground

circuit of engine ECU
- Memo -
01
02
03
04
05
06
07
08
09
10
Usage and Maintenance of Engine
(Gasoline Engine) 01
Cautions .......................................................................05-1
General Cautions......................................................05-1 02
Cautions Notable for Operation and Flameout .........05-1
Cautions for Engine ..................................................05-2 03
Cautions for Starter ..................................................05-2
Usage...........................................................................05-3 04
Fuel, Oil and Cooling Water......................................05-3
Preparation before Start ...........................................05-3 05
Start of Gasoline Engine...........................................05-4
Idling and Warm-up ..................................................05-4
Operation of Gasoline Engine...................................05-5 06
Shutdown of Gasoline Engine ..................................05-5
Maintenance Contents .................................................05-6 07
Routine Maintenance................................................05-6
Maintenance after Every 1,000km ............................05-7 08
Maintenance after Every 3,000km ............................05-7
Maintenance after Every 6,000km ............................05-7 09
Seasonal Maintenance .............................................05-7
Maintenance of Various Sub-systems..........................05-8
10
Maintenance of Lubrication System..........................05-8
Maintenance of Cooling System .............................05-10
Maintenance of Fan Belt .......................................05-11
Maintenance of Fuel System ................................05-11
Maintenance of Air Intake System ........................05-12
Maintenance of Valve Train and Timing Belt ........05-13
Maintenance of Spark Plug ...................................05-14
Maintenance of Positive Crankcase Ventilation
Valve (PCV Valve)..................................................05-14
Oil Sealing & Storage and Unsealing of Gasoline
Engine ......................................................................05-15
Oil Sealing and Storage of Gasoline Engine...........05-15
Unsealing of Gasoline Engine ................................05-15
List of Service Period and Maintenance
Contents of Gasoline Engine .....................................05-16
01
02
03
04
05
06
07
08
09
10
Usage and Maintenance of Engine (Gasoline Engine) - 05-1
Cautions
Cautions
General Cautions
01
1. When the gasoline engine is used, its adjustment and maintenance shall be subject to the
maintenance methods and relevant provisions introduced in this Manual. 02
2. When a new gasoline engine overhauled gasoline engine is used, it must be run in according to
relevant provisions, and never allow sudden acceleration and early loading. 03
3. When the gasoline engine works, the normal coolant temperature shall be kept at 80~95℃. The
normal oil pressure is 245~392kPa at medium speed, and the oil pressure warning lamp goes out 04
(this lamp shall come on before the gasoline engine starts).
4. It is unallowable for the gasoline engine to run with problems. When the low oil pressure, no oil
pressure, overhigh coolant temperature or internal abnormal noise of the gasoline engine is 05
detected, the vehicle shall be stopped for inspection and troubleshooting.
5. Attention shall be paid to the fire protection of the gasoline engine, and open fire is strictly prohibited 06
to be close to the gasoline engine. When the injection of the fuel injector is checked, injecting fuel to
the air is strictly prohibited to avoid explosion and burning due to meeting sparks. 07
6. For repair or removal of the fuel pipeline, make sure to use cotton cloth, plastic cloth or similar
articles to wrap joints and then slowly disconnect the joints to prevent gasoline from splashing. 08
7. Usually check the airtightness of the whole fuel circuit, and immediately eliminate fuel leakage if
any.
09
8. The pistons of the first and fourth cylinders of the gasoline engine stay in the top dead center, the
falling edge of the 20th tooth (count from the position short of two teeth counterlockwise) of the
signal gear shall correspond to the crankshaft position sensor installed, and make sure that the 10
clearance between the crankshaft position sensor and signal gear top is within 0.7~1.2mm.
9. The screw at the idle position of the gasoline control throttle has been adjusted in the factory, and
self-adjustment is not allowed.
10. The fuel pressure regulator of the gasoline engine has been adjusted correctly, and self-adjustment
is not allowed.
11. When the gasoline engine stays in cold state, the speed of either the neutral gear or the moving
gears shall not be exceeded; while it stays in warm state, the running speed of each gear and the
speed of the gasoline engine can be normal.
12. When the malfunction indicator lamp comes on in vehicle's running process, the driver must stop
the vehicle to find the fault, read the fault code and report it to the authorized service center of that
accessory, and the authorized service center will judge whether the vehicle is suitable for continuing
running.
Cautions Notable for Operation and Flameout

1. Check whether there is knock, bang, looseness or other abnormal noise (especially after fuel filling
and maintenance).
2. Check whether there is abnormal burning smell given out from electrical equipment due to high
temperature.
3. Check whether the fuel system, cooling system and lubrication system leak.
4. Check whether the readings of instruments for oil pressure, coolant temperature, current, fuel level
are normal.
5. When the gasoline works, carefully listen to whether there is abnormal noise, usually check whether
the joints in each oil passage, water passage and air passage leak, and immediately eliminate
leakage if any. Otherwise, it will cause major fault.
6. When the gasoline engine runs, operators are not allowed to stand near its rotating parts, and
removal is strictly prohibited when the gasoline engine runs. For necessary inspection and
adjustment, pay attention to the safety.
7. When the gasoline machine runs with large load, before shutdown, reduce its speed to low speed
for 2~3min of running, and then turn off the ignition switch. This aims to have the gasoline engine
cooled gradually and evenly, so as to avoid change in parts due to sharp cooling.
05-2 Usage and Maintenance of Engine (Gasoline Engine) -
Cautions
Cautions for Engine

1. The center of the generator pulley shall be aligned with that of the drive pulley, and the belt shall not
01
too tight or loose, which will have an influence on the reliability and service lift of the generator.
2. The generator must work in parallel with the battery and match with the regulator of proper model,
02 and the wire connection shall be firm and reliable.
3. The negative pole of the generator shall be grounded, and also the negative pole of battery shall be
03 grounded, otherwise the generator and regulator will be damaged by burning.
4. The multimeter will be used for checking whether the generator generates power, and the test
04 method of generating power to the ground is not allowed for inspection.
5. Usually clear away dust and oil dirt from the generator, and keep wire connection in good condition.
05 6. The maintenance shall be available for the generator for every 1,000 hours of operation, check
whether brushes are worn, clean bearings and fill an appropriate amount of lubricating oil; the filling
amount of lubricating oil shall be 2/3 of the bearing housing, and double sealed bearings are
06 maintenance-free.
7. In generator's running process, never disconnect or connect each connecting wire to avoid short
07 circuit and burning the silicon rectifier.
8. When the silicon rectifier is connected with the stator coil, never use a megohmmeter or 200v AC to
08 check the insulation of the generator; otherwise, diodes will be damaged by breakdown.
09 Cautions for Starter

10 1. Check the gasoline engine before use, and start the starter after confirming that the gasoline engine
can work normally.
2. When starting the gasoline engine, pull the ignition switch key to “START” position, and the gasoline
engine will be started by the starter. Once the gasoline engine is on, release the key immediately to
cut off the power of the starter.
3. The gasoline engine management system will provide appropriate air/fuel ratio for mixing air and
fuel and ignition advance angle. Therefore, under any weather conditions, it is unnecessary to step
on the accelerator.
4. If the gasoline engine fails to start after trying several times, there may be the short circuit fault of
the spark plug due to fuel spill. Under this condition, step on the accelerator pedal completely, then
start the gasoline engine (at the time the electronic controller will control nozzles to cut off fuel
supply), and spilled fuel will be removed by the blowing of jet stream within 5s. At the moment,
release the accelerator pedal, and re-start the gasoline engine.
5. The working time of the starter shall not exceed 5s every time. If the gasoline engine fails to start,
start it again after an interval of 10s; otherwise, the starter may be damaged.
6. Usually check whether the insulation of wires is damaged.
7. The starter shall be overhauled yearly, and the overhaul period can be appropriately shortened or
extended according to its condition.
Usage
Usage
Fuel, Oil and Cooling Water
01
1. Fuel
Users shall select gasoline type according to the local ambient temperature; when the ambient 02
temperature is higher than -20℃, SF 15W/40 gasoline is applicable, and when the ambient
temperature is lower than -20℃, SF 5W/30 gasoline is applicable (GB 11121-1995). 03
2. Oil
Users shall select oil type according to the local ambient temperature; when the ambient 04
temperature is higher than -20℃, SF 15W/40 oil is applicable, and when the ambient temperature is
lower than -20℃, SF 5W/30 oil is applicable. Great Wall, Tongyi or Kunlun lubricating oil is 05
recommended. Remove the filler cap on the cylinder head cover and then fill the gasoline engine
with oil. Remove the oil drain bolt from the oil pan to drain oil. 06
3. Cooling Water
Rain water or clean river water is applicable. The tap water from wells is inapplicable. In the cold
winter, antifreeze is available for the cooling system to prevent freezing. The antifreeze most 07
commonly used is 50% of glycol (DEG) and 50% of water (volume ratio), or 43% of alcohol, 15% of
glycerol and 42% of water (weight ratio). When the ambient temperature is lower than 0℃ and the 08
gasoline engine is hard to start, heat the cooling water to above 80℃ and fill the water tank of the
gasoline engine. 09
Preparation before Start 10
Caution:
Before starting and using the gasoline engine, operators shall carefully read this Usage and
Maintenance Manual for Gasoline Engine, and strictly follow the requirements of this Manual for
operation.
1. Carefully check whether the parts of the gasoline engine are normal, and the connection is correct
and firm.
2. Check the coolant level in the reservoir (radiator), the tightening condition of pipe joints and the
tightness of fan belts, and note that correct coolant is used and its correct level can be achieved
only under the condition of engine shutdown.
3. Check whether the oil level indicated by the dipstick meets the requirement and oil degrades or
ages. It shall be noted that the level at the lower scale of the dipstick is the warning level, but not the
service level. Fill up with oil according to relevant provisions duly to avoid accidents.
4. Check the fuel level in the fuel tank and the good condition of pipelines and joints of the fuel system,
and eliminate leakage and air in pipelines.
5. Check the electrolyte level of the battery.
6. Check the tightening condition of joints on the battery, generator, starter, spark plug, ignition coil
and ECM electrical equipment.
Usage
Start of Gasoline Engine

Caution:
01
If the preparation work is not ready, the gasoline engine is not allowed to start. Check whether
there are articles to interfere with its work on, behind and around it first, and then start the
02 gasoline engine after confirming that there are no problems.
03 1. Place the gear shift level of the transmission to the neutral position.
2. Step on the clutch pedal to reduce the load at the start of the gasoline engine.
04 3. The electronic fuel injection system will provide appropriate air/fuel ratio all the time under all
conditions, and the accelerator pedal will not be stepped on for both hot start and cold start,
05 because ECM determines the condition of the gasoline engine according to the position of the
throttle. Once the accelerator pedal is stepped on, the throttle will be opened, ECM is unable to
determine the condition of the gasoline engine, and accurate fuel supply is inaccessible.
06 4. Turn the ignition switch key to “START” position to start the gasoline engine.
5. The first start (a new vehicle or the fuel supply system repaired just now) may consume a long time,
07 because the oil pipe needs time to be filled with fuel to proper fuel pressure.
Caution:
08 (a). The start time shall not exceed 5s every time to protect the starter and battery; if the gasoline
engine fails to start once, the interval for re-starting the engine shall not be less than 15s. If
09 the three successive starts of the gasoline engine fail, a new start shall be applied after
cause finding and troubleshooting.
(b). The oil warning indicator lamp comes on in start process.
10
After the gasoline engine starts, the ignition switch key shall be released immediately to let
the key automatically return to “IGNITION” position, and the gasoline engine stays at fast
idle speed at the time if cold-started. As its temperature rises, the gasoline engine will
automatically, gradually fall to normal idle speed.
(c). After the gasoline engine runs normally, the oil warning indicator lamp goes out.
Idling and Warm-up

After start, the gasoline engine needs to run at idle speed for several minutes to warm up. The gasoline
engine in cold state runs at higher speed under the control of ECM to warm up, and with the temperature
rise of coolant, the idle speed will fall to the normal idle speed.
When the ambient temperature is lower than -10℃, the gasoline engine shall warm up for 5min before
the vehicle moves.
When the air conditioner is switched on at idle speed, the idle speed of the gasoline engine will increase
by 150r/min.
Usage
Operation of Gasoline Engine

1. Check whether there is knock, bang, looseness or other abnormal noise (especially after fuel filling
01
and maintenance).
2. Check whether there is abnormal burning smell given out from electrical equipment due to high
temperature. 02
3. Check whether the fuel system, cooling system and lubrication system leak.
4. Check whether the readings of instruments for oil pressure, coolant temperature, current, fuel level 03
are normal.
Caution: 04
(a). When the gasoline engine runs, operators are not allowed to stand near its rotating parts,
and removal is strictly prohibited when the gasoline engine runs. For necessary inspection 05
and adjustment, pay attention to the safety.
(b). When the gasoline works, carefully listen to whether there is abnormal noise, usually check
whether the joints in each oil passage, water passage and air passage leak, and immediately 06
eliminate leakage if any. Otherwise, it will cause major fault.
07
Shutdown of Gasoline Engine 08
When the gasoline machine runs with large load, before shutdown, reduce its speed to low speed for
2~3min of running, and then turn off the ignition switch. This aims to have the gasoline engine cooled 09
gradually and evenly, so as to avoid change in parts due to sharp cooling.
10
Maintenance Contents
Tip:
01 In engine’s use process, the wear of parts, looseness of fasteners, change of clearance and degradation
of oil will worsen the technical condition of the gasoline engine, which will cause many abnormal
phenomena such as difficult start, decreased power and increased oil consumption, even failure to
02
normally work. According to the technical condition and working hours of the gasoline engine or the
travelled mileage of the vehicle, regularly apply the technical maintenance such as the cleaning,
03 inspection, lubrication, adjustment or replacement of some parts for each part of the gasoline engine,
which is an important content for reasonably using the gasoline engine.
04
Routine Maintenance
05 Tip:
In order to ensure the normal running of the gasoline engine, the maintenance work shall be subject to
06 the following procedures in engine’s use process.
07 1. Check the levels of gasoline, coolant and oil, and fill up according to the requirement if necessary.
Caution:
08 (a). Only after the gasoline engine is shut down and the vehicle is stopped at a flat place for a
period of time, the correct levels can be achieved. The gasoline engine shall use premium
unleaded gasoline above 93# (GB17930-1999).
09 (b). Never fill up the fuel tank with fuel when the gasoline engine runs. If the vehicle runs under
hot weather, the fuel tank shall not be filled up; otherwise, fuel will spill by expansion.
10 Immediately wipe off fuel if spilling.
2. Clear away the dirt and splashed electrolyte on the battery to ensure the small air vents are clear.
Under the normal use condition, the battery is nearly maintenance-free, and the electrolyte level
shall be checked regularly at high temperature. The electrolyte level shall stay between the MIN and
MAX marks at the side of the battery. When the electrolyte in the battery is not enough, the battery
shall be filled with distilled water duly.
Caution:
(a). Never fill the battery with make-up fluid or unclean water freely; otherwise, it will cause
undercharge and have an influence on use. If the level of the battery falls quickly, the
battery shall be delivered to the service station for repair.
(b). As the acid solution is corrosive, it shall be away from eyes and skin; if touched, wash
with clean water immediately.
3. After the gasoline engine starts, check whether there are the phenomena of leaking oil, water, gas,
electricity, etc. The above problems if any shall be eliminated duly.
4. Check whether the joints of high tension cables are loose.
5. After the gasoline engine starts, listen to whether its running is normal, and check the working
condition of instruments.
Maintenance after Every 1,000km

1. Finish the contents of routine maintenance.
01
2. Check the specific gravity or voltage of the battery electrolyte.3. Check whether the joints of the
generator, ignition coil, spark plug, anti-interference high tension cable and electrical accessories
are loose. 02
4. Clean the air filter.
5. Check the fastening condition of fasteners of the gasoline engine. 03
Maintenance after Every 3,000km 04
1. Finish the contents of maintenance after every 3,000km. 05

2. Clean the spark plug electrode and adjust electrode clearance.
3. Clean the paper-element air filter or replace the element. 06
4. Check the fastening condition of connecting rod bolts, main bearing bolts and flywheel bolts.
Caution: 07
(a). When removing the air filter, never start the gasoline engine to prevent the wear of relevant
parts due to unfiltered air going into the cylinder.
08
Maintenance after Every 6,000km 09
1. Finish the contents of maintenance after every 3,000km.

10
2. Clean the gasoline tank, check whether the gasoline line is normal, and replace the gasoline filter.
3. Check whether the battery cracks or leaks electricity.
4. Check whether the working condition of the generator is normal.
5. Replace the oil in the oil pan.
Caution:
(a). 10W/30 (or 15W/40) oil above SF grade is available, and 5W/30 oil shall be used in winter.
Other models of oil or inferior oil is unacceptable, and the mixed use of different grades of
oil is unacceptable either.
If the vehicle runs at a dusty area or at a cold area where the temperature is lower than -20℃,
the replacement period of oil shall be shortened accordingly.
6. Replace the oil filter or element (appropriately in advance or later time according to the practical
condition).
7. Clean the PCV valve and its breather of the gasoline engine to clear away attachments and ensure
their normal function.
Seasonal Maintenance
1. Recommend replacing extended life coolant once per year.
2. Use winter oil duly in winter.
3. Change the concentration of battery electrolyte according to different seasons.
Maintenance of Various Sub-systems

Maintenance of Lubrication System
01
1. Oil for Gasoline Engine
02 Lubricating oil shall be selected for the lubrication system of the gasoline engine according to the
ambient temperature.
03 10W/30 oil and 15W/40 oil (GB11121) above SF grade are respectively applicable for the south
central area in winter and summer, and SF 5W/30 oil is applicable for the northeast of China.
Tip:
04
After the vehicle with a new gasoline engine runs in for 2,500km and normally runs every 5,000km,
oil must be replaced; the mixed use of different grades of oil is unacceptable.
05 2. Measurement for Oil Level of Gasoline Engine
The oil volume of the oil pan will be measured by the dipstick installed at the right side of the
06 gasoline engine. The measurement shall be made after about 5min from the shutdown of the
gasoline engine; take out the dipstick, wipe off oil with clean cloth, and then insert into the oil pan to
07 measure the oil level. Check the oil level before driving. The oil level shall stay between the upper
and lower limits of the dipstick. If the level is close to or lower than the lower limit, oil shall be added
08 to the upper limit.
3. Replacement of Gasoline Engine Oil
Replacement by new oil: If the vehicle runs on asphalt road, replace the used oil with the new every
09 5,000km; if the vehicle runs on adverse sand and soil road, check oil usually, and replace according
to oil condition duly, but not more than 5,000km.
10 Replacement method:
(a). Place the gasoline engine or stop the vehicle on a flat position.
(b). Start the gasoline engine, and allow the temperature of lubricating oil to reach 80℃;
(c). Shut down, place an oil drip pan, and unscrew the drain plug to drain oil.
Caution:
Pay attention to not being scalded by oil when unscrew the drain plug.
(d). Place new wash, screw up the drain plug, and tighten according to the specified torque.
(e). Add about 3L of oil from the filler cap, and then put on the filler cap.
(f). Start the gasoline engine and let it run for 5min, check whether oil is leaked, shut down and
check the level after 5min, and add oil to the upper limit of the dipstick when the oil in the oil pan
is not enough.
4. Oil for Transmission
Reasonable use of lubricating oil by the gasoline engine and transmission is a key factor to endure
its good working and service life. Users shall pay special attention to choosing oil, and the mixed
use of oil with different origins, grades and standards is not allowed to prevent different oil types
from causing chemical reaction which has an influence on the normal running of the gasoline
engine.
Oil with unspecified grade is unacceptable, and never use imported oil.
5. Replacement of Transmission Oil
Replace the gear oil of the transmission once every 40,000km (except the running-in stage).
When replacing the gear oil of the transmission, allow the gasoline engine to warm up for 10min,
unscrew the oil filler plug and drain plug on the back-extended case of the transmission, drain the oil
in the transmission, screw up the drain plug, and fill with 1.2L~1.3L of gear oil from the oil filler.
6. Cleaning of Lubrication System
If a great amount of impurities are accumulated in the oil pan, clean the lubrication system of the
gasoline engine with light spindle oil, and gasoline or kerosene is prohibited for cleaning.
Cleaning method of gasoline engine inside:
(a). Fill the gasoline engine with 3L of light spindle oil from the oil filler.
(b). Start the gasoline engine to the idle speed by the starter twice or three times, 1min for each
time, and then drain the spindle oil for cleaning quickly.
(c). Fill the gasoline engine with oil according to relevant previsions.
(d). After oil is replaced each time, the gasoline engine shall run for 3~5min under no-load condition
to ensure enough oil is supplied to the lubrication system and oil-lubricated parts.
7. Replacement of Oil Filter 01
The oil filter shall be replaced with a new one every 10,000km.
The tightening torque is 12~16N•m for installation. 02
8. Inspection of Oil Pressure Indicating System
Under normal condition, when the power switch (key) is pulled to “ON” position, the oil pressure
03
warning indicator lamp comes on, which indicates there is no oil pressure;
When the switch is pulled to “START” position from “ON” position, the gasoline engine runs at idle
speed, and the oil pressure warning indicator lamp goes out at the time, which indicates the oil 04
pressure is normal.
If the oil pressure warning indicator lamp does not go out, which indicates the oil pressure in the 05
lubrication system of the gasoline engine is abnormal. First of all, check whether the oil volume in
the gasoline engine is enough. 06
When the switch is pulled to “ON” position, the oil pressure warning indicator lamp does not come
on, and the grounding between the oil pressure switch and engine body is in closed circuit; the 07
grounding between the oil pressure switch and engine body is in broken circuit in idle state, which
indicates the oil pressure switch is in good condition. At the moment, check whether there are faults
in the indicator lamp and relevant circuit. 08
09
10
Maintenance of Cooling System

Tip:
01
The cooling system is one of prerequisites to ensure the normal working of the gasoline engine, so it is
necessary to ensure there is enough coolant in the gasoline engine. Check before driving, and fill duly
02 when the coolant is not enough.
03 1. Coolant
Distilled water or appropriately-treated soft water and antifreeze can be used as coolant for this
04 series of gasoline engines, and the freezing point of the antifreeze shall be 5℃ lower than the local
minimum temperature.
05 When water is used as coolant in winter, a warming garage must be provided for heat preservation
to avoid the coolant from icing, or the cooling water of the radiator and gasoline engine is drained
duly after the vehicle is parked, so as to avoid the frost cracking of the radiator and gasoline engine.
06 For the gasoline engine without water drain plug on the cylinder, water can not be used as coolant in
winter.
07 Tip:
The volume of water will expand after icing, which will burst the sealed radiator, water pump,
08 cylinder head and cylinder.
2. Coolant Filling
09 Fill with coolant according to the following step:
(a). Unscrew the radiator cap, fill up the radiator with coolant, and allow the coolant level of the fluid
reservoir to reach “FULL” scale. Note that the coolant level is not allowed to exceed “FULL”
10
scale.
(b). Put on the radiator cap and tighten.
(c). Start the gasoline engine, allow it to run at idle speed for 2~3min, and unscrew the radiator cap.
At the time, the coolant level falls down as air existing in the water passage was eliminated.
After that, fill with coolant to reach “FULL” scale.
3. Coolant Adding
After long-term use, when the coolant level of the fluid reservoir is lower than “LOW” scale, coolant
shall be added according to the coolant filling steps.
If the coolant level drops down sharply within a short time, the cooling system may leak, and check it
carefully.
4. Coolant Replacement
After long-term use, when coolant needs replacing due to coolant degradation, repair, etc., replace
coolant according to the following steps:
(a). Unscrew the radiator cap, open the water drain valve at the bottom of the radiator, and drain the
coolant.
(b). Remove the fluid reservoir, and empty it.
(c). Unscrew the water drain plug on the crankcase, and drain the coolant.
(d). Install the fluid reservoir, close the water drain valve of the radiator, screw up the water drain
plug of the crankshaft, and fill with coolant according to the coolant filling steps.
Tip:
When the coolant is replaced, the vehicle shall be stopped at a flat position.
Caution:
Not installing the thermostat assembly after removal is strictly prohibited. Not installing the
thermostat assembly will extend the warm-up time after the start of the gasoline engine, and
the gasoline engine’s running at low temperature for a long time will result in serious wear of
parts, which will have an influence on its service life.
Maintenance of Fan Belt

Tip:
01
The fan belt is used to drive the generator, water pump and fan, so the fan belt shall be checked and
maintained usually.
The deficient tension or damage of the fan belt will cause generator overheating and decreased power 02
generation of the generator.
03
1. Adjustment
Check the tightness of the fan belt. Exert about 98N force to the fan belt; the reduction of the new 04
fan belt is about 7~10mm, and the reduction of the old fan belt is about 10~15mm.
2. Appearance 05
The appearance of the fan belt shall be good, and replace it duly if there are defects affecting its
use.
06
Maintenance of Fuel System 07

1. Fuel Line
As the fuel pressure in the fuel line of the EFI gasoline engine is high, the part on the fuel feed pipe
08
and fuel return pipe shall be tightened by clamps, and leakage is not allowed. Usually check the
airtightness of the whole fuel circuit, and immediately eliminate fuel leakage if any.
Caution: 09
(a). When the fuel line is checked, it is strictly prohibited to start the gasoline engine after
the fuel injector, fuel rail assembly and fuel pipe are removed. Injecting fuel to the air is 10
strictly prohibited, and fuel leakage may cause fire.
(b). For repair or removal of the fuel pipeline, make sure to use plastic cloth or similar
articles to wrap pipe joints to prevent gasoline from splashing. Pay attention to not
smoking or firing to cause fire or other dangers.
2. Fuel Filter
The fuel filter needs replacing every 6,000km.
Caution:
An arrow is marked on the fuel filter shell to indicate the flow direction of gasoline. The fuel
filter shall never be installed reversely; otherwise, a new fuel filter must be used for replacing
the reversely-installed one.
3. Fuel injector
When the vehicle is not used for a long time, the gasoline engine shall be started to run for 5~10min
once every 1~2 months to prevent the fuel injector from jamming. Under normal condition, the fuel
injector shall be cleaned with ultrasonic waves every 20,000km. When the removal-free cleaning is
available, make sure that the additives used do not contain substances harmful to the oxygen
sensor and three-way catalytic converter.
4. Throttle Body
Under normal condition, the throttle body shall be cleaned every 20,000km or yearly.
Maintenance of Air Intake System

1. Air Filter
01
Remove the air filter, take out the element, confirm whether the element is too dirty, deforms, is
damaged or is oily through visual inspection, and replace it if necessary.
02 When the element is contaminated by dust but stays in dry state, clean it with compressed air.
During cleaning, blow away dust from inside to outside by compressed air while rotating the element
03 by hand, and then clean the outside of the element by blowing.
Caution:
04 (a). Never blow away dust from outside to inside by compressed air, which will blow dust into the
inside of the element.
05 (b). Paper elements shall not be cleaned by any cleaners or water.
Clean the inside of the air filter shell and intake connecting pipe.
Pay attention to their airtightness when installing the element and air filter. If the airtightness is
06 imperfect, unfiltered air will go into the cylinder.
2. Intake Line
07 Check the airtightness of the joint between the intake line and air filter, deal with the leakage if any
immediately, replace the gasket and tighten connecting parts.
08
09
10
Maintenance of Valve Train and Timing Belt

Tip:
01
The valve train and timing belt shall be checked and maintained usually. Once the timing belt is broken
or slides, the valve will collide with the piston, which will cause damages to the valve, piston, rocker air,
camshaft and other parts. Therefore, except the running-in stage of the vehicle, check it once every 02
20,000km, and appropriately adjust and replace it if necessary.
03
1. Inspection and Adjustment of Timing Gear
Open the toothed belt cover, check whether the assembly mark position of the driving and driven 04
timing gears, and check according the following if the timing is incorrect or in doubt.
Remove the spark plug, refer to the flywheel scale in the observation hole in the transmission 05
housing, then rotate the flywheel according to the working direction of the engine to align the
keyway at the front end of the crankshaft with the arrow on the inner cover of the toothed belt, and
check that the piston of the first cylinder of the engine stays at the top dead center of the 06
compression stroke, namely that there are gas between the intake and exhaust valves and rocker
arm adjustment screw. If it is not right, rotate the crankshaft by 360°, and the round pit mark 07
(opposite to the key) on the edge of the driven timing gear shall be aligned with the arrow on the
inner cover of the toothed belt at the moment; if the mark is not aligned with the arrow in a large 08
degree, adjust it.
Rotate the crankshaft by 360° to allow the first cylinder to stay at the top dead center of the exhaust 09
stroke and the fourth cylinder to stay at the top dead center of the compression stroke, and one of
the two marks on the edge of the driven timing edge shall be aligned with the triangle mark on the
10
tooth belt cover.
2. Timing Belt
Check whether there are the following items for the timing belt:
(a). Hardening of belt back. The back is glossy and inelastic, and hardens. No marks appear when
the back is pressed by fingernail.
(b). Cracking of belt back.
(c). Cracking or fabric peeling.
(d). Tooth wear (early stage). The fabric at the bearing edge of teeth is worn. The side is worn.
(d). Tooth wear (later stage). The fabric at the bearing edge of teeth is worn off, and rubber is
exposed (the tooth thickness thins).
(f). Cracking of tooth root.
(g). Tooth falling.
(h). Wear of belt side. The belt side fluffs at the whole circumference.
(i). Cracking of belt side.
Immediately remove the above items if any, and replace the timing belt if it is seriously worn.
Under normal condition, the timing belt shall be replaced every 100,000km.
Maintenance of Spark Plug

The spark plug shall be replaced every 10,000km. The spark plug can be replaced immediately if
01
damage is detected in the usual inspection; its model is F6RTC, and its thread is M14X1.25.
The surfaces of the center electrode insulator and side electrodes of the spark plug shall be clean, free
02 from carbon deposit; the carbon deposit if any can be cleared away with fine abrasive paper.
The spark plug gap is 1~1.2mm, and the gaps on the plane of the whole center electrode shall be even
03 and equal.
04 Maintenance of Positive Crankcase Ventilation Valve (PCV

05
Valve)
The PCV valve, as composed of a valve body, a valve, a bonnet and springs, is indecomposable. Its
06 main function is to introduce waste gas in the crankcase into the intake manifold, and the waste gas will
be burnt finally, which prevent the waste gas from polluting the environment.
07 Remove the PCV valve every 10,000km, wash with gasoline and dry by blowing, and then push by a
steel wire its valve which shall move flexibly. The valve must be replaced if jammed or blocked.
08
09
10
Oil Sealing & Storage and Unsealing of Gasoline Engine
Oil Sealing & Storage and Unsealing of Gasoline Engine

Oil Sealing and Storage of Gasoline Engine
01
1. Drain the coolant in the radiator and cylinder.
2. Clean the outside surface with washing gasoline. 02
3. When the gasoline engine is in hot state and the pistons stay between the top and bottom dead
centers, unscrew the spark plug of each cylinder, fill each cylinder with 10~15g of antirust oil, rotate 03
for 3~5 circles, screw up each spark plug according to the specified tightening torque, and block the
exhaust pipe.
04
4. Wrap or seal the pipe orifice of the throttle body, the inlet and outlet hose orifices, and the bush of
the tachometer by wax.
5. Place the gasoline engine into the packing box. 05
6. The gasoline engine shall be stored in such a warehouse that is dry, ventilated, and free from
corrosive substances. 06
Unsealing of Gasoline Engine 07
1. Clear away the grease at the outside of the gasoline engine. 08

2. Unscrew the spark plug, idle the gasoline engine, and drain the antirust oil in the cylinders as much
as possible. 09
3. Fill with oil.
4. Fill with coolant. 10
5. Unseal all sealed holes.
List of Service Period and Maintenance Contents of Gasoline Engine
List of Service Period and Maintenance Contents of

Gasoline Engine
01
The service period shall be Km*1000 2.5 10 20 30 40 50 60 70 80
02 judged by the odometer or
month, whichever is shorter. Month 2 6 12 18 24 30 36 42 48
03
Belt, Generator (Check elasticity
1 A - I - R I I - R
04 and wear)
Timing Belt (Check damage and
2 - - I - I - I - I
05 wear)
Clearance between Intake and
3 A - A - A - A - A
06 Exhaust Valves
Tightening Torque, Bolts of
07 Cylinder Head and Fixing Bolts
4 T - T - T - T - T
and Nuts of Intake and Exhaust
08 Manifolds
5 Oil Filter R R R R R R R R R
09
6 Gasoline Oil Replace once every 5,000km
10
Fuel Hose and Joint (Aging of hose
7 ages, and cracking or damage of I I I I I I I I I
joint)
Hose and Joint, Gasoline Engine
8 Cooling System (Water leakage, - - I - - I - - I
damage, etc.)
Anti-interference High Tension
9 - - I - - I - - I
Cable (Degradation and damage)
10 Spark Plug - R R R R R R R R
Gasoline Pump (Whether it leaks

11 - - I - I - I - I
gasoline)
Clean once every 10,000km for asphalt road
12 Air Filter
Clean once every 2,500km for dusty road
Accelerator Control Cable and I I I I I I I I
13 -
Throttle Body Shaft L L L L L L L L
Idle Speed and Emission at Idle
14 A A A A A A A A A
Speed
15 PCV Valve - I I I I I I I I
16 Clutch Clearance - I I I I I I I I
Transmission Gear Oil (Check

17 R I I I R I I I R
leakage in horizontal state)
Meaning of the above letters:

A – Inspection or Adjustment L – Lubrication R – Replacement
I – Inspection, Adjust or Replace if Necessary T – Inspection according to Special Torque Wrench
Complete Engine Set
Removal and Installation of Complete Engine Set .......14-1
Cautions ...................................................................14-1 01
Removal Steps .........................................................14-2
Installation Steps ......................................................14-4 02
Instructions for Key Points ........................................14-6
Storage of Complete Engine Set..................................14-8 03
04
05
06
07
08
09
10
01
02
03
04
05
06
07
08
09
10
Complete Engine Set - Removal and Installation of Complete Engine Set 06-1
Removal and Installation of Complete Engine Set

Cautions
01
1 Park the vehicle on a vehicle groove or vehicle repair stand.
2 Set the parking brake lever in the parking position.
02
3 Fix the wheels with trigs or wedges which shall be arranged against the front and rear sides
of types; it is preferable to fix both side wheels.
4 Stall the engine while operating under the chassis; switch off the ignition switch (in the OFF 03
position).
5 Arrange a marker indicating “No Starting” in the position of the steering wheel or on the 04
driver’s seat while operating under or behind the vehicle.
6 Keep away from a fire while removing the Complete Engine Set. 05
7 Disconnecting any part connected with the engine; arrange the disconnected parts in the
positions having no influence on removal; fix the parts on the frame with cables and mark 06
them.
14
07
08
09
10
06-2 Complete Engine Set - Removal and Installation of Complete Engine Set
Removal Steps
1. Disconnect positive and negative leads of the battery.
Tip:
01 In order to avoid the danger of electric spark caused by accidental grounding of the wrench during
removal, the negative and positive leads of the battery shall be removed in order.
02 2. Discharge engine coolant.
3. Discharge engine lubricating oil.
03 Tip:
The discharge of engine lubricating oil shall depend on whether the engine needs maintaining or not.
04 4. Remove the driver’s and co-driver’s seats.
5. Remove the transmission control mechanism and the service brake control mechanism.
6. Remove the supporting plate of the service brake control mechanism.
05
7. Lift the rear mat and remove the rear inspection cover of the engine.
8. Remove the cargo box.
06 Tip:
Removing the cargo box is convenient for removal and installation the complete engine set.
07 9. Disconnect all the cooling lines connected with the engine; remove the cooling lines when
necessary.
08 Tip:
It is recommended to remove the inlet and outlet hoses of the engine as much as possible so as to avoid
09 damage.
10. Disconnect the water temperature sensor lead on the intake manifold.
11. Disconnect the accelerator cable from the throttle valve.
10 12. Disconnect the connecting leads of all the sensors.
13. Disconnect the fuel feed pipe and the fuel return pipe connected with the engine.
Tip: The removed fuel lines must be sealed and fixed in the frame crossbeam groove.
14. Disconnect the heater hose connected with the engine.
15. Remove fixing clamps for the intake hose of the engine; remove the intake hose and seal the
port of the intake manifold.
16. Remove the lead of the oil pressure warning unit.
17. Disconnect the engine grounding wire connected with the transmission; remove the leads
connected with the generator and the starter.
18. Remove the air filter component.
Tip:
The joints shall be sealed after removal.
19. Disconnect the three-way catalytic converter from the exhaust manifold.
Tip:
For facilitating the removal and installation of the complete engine set, remove the three-way catalytic
converter and the muffler of the exhaust pipe as possible.
20. Disconnect the clutch cable and the clutch shift fork arm from the engine installation parts
and the clutch lever.
21. Remove the control cable on the transmission and the sensing lead of the speedometer.
Tip:
The disconnected cable on the transmission shall be fixed in the groove on the beam of the frame.
22. Disconnect the reverse switch cable and mileage sensor lead from the reverse switch.
23. Disconnect the drive shaft from the transmission.
24. Place the jack under the engine; select a suitable position to slightly support the engine;
install the safety ropes.
Tip:
• While remove the engine by using the jack, the engine must be fixed with the safety ropes on the
jack so as to prevent the engine from inclining and falling during movement and descending.
• The factor of the load capacity of the brackets shall be considered sometimes. While removing the
engine assembly, the transmission can also be removed before removing the engine so as to 01
reduce the load of the brackets.
• When necessary, the bottoms of the transmission and the engine can be jacked by two brackets. 02
• Make sure that all the leads and lines around the engine are disconnected from the engine.
25. Remove engine suspension fixing bolts connected with the frame.
03
26. Remove suspension fixing bolts at the rear end of the transmission.
27. Jack the engine a little steadily; move the engine slowly to a suitable angle after the front
engine suspension is disconnected from the suspension supports. 04
28. Lower both brackets slowly.
Tip: 05
Before removing the engine, it shall be re-examined whether all the connections around the engine are
disconnected. 06
29. Push the vehicle backwards or forwards so as to expose the engine in the vehicle groove;
release the safety ropes on the brackets; hoist the engine from the floor groove by hangers; 07
and place the engine on the removing stand slowly.
14 08
09
10
Installation Steps
1. Place both brackets in the vehicle groove; arrange the engine with the transmission
assembly steadily on the brackets in the vehicle groove by using the hanger; fasten the
01 engine on the brackets by using the safety ropes on the brackets.
Tip:
02 Because the engine with the transmission assembly is quite heavy, two or more persons shall be
preferred for installation so as to avoid accidents.
03 2. While pushing the vehicle into the vehicle groove, the engine shall correspond to the
mounting position on the frame.
04 3. Jack both brackets slowly at the same time; approach the engine suspension on the
crossbeam; align the fixing bolt holes.
4. Install and fasten the fixing bolts for front engine suspension.
05
5. Install the rear engine support on the frame cross member by using the brackets; install and
fasten the fixing bolts.
06 Tip:
After making sure that both the front and rear fixing bolts for the engine suspensions are firmly installed,
07 the engine brackets shall be slowly lowered and then removed for convenience of installing the engine
connecting pieces.
08 6. Install the drive shaft and the fixing bolts; fasten the fixing bolts.
7. Firmly plug the reverse switch leads into the transmission reverse switch lead connectors.
09 8. Install the control cable of the transmission and the lead of the speedometer sensor on the
transmission
9. Install nuts for connecting the clutch cable and the clutch fork shaft arm.
10 10. Install the three-way catalytic converter and muffler; install the joint gasket for connecting
the three-way catalytic converter with the muffler; install and fasten the fixing bolts.
11. Install the carbon vacuum pipe on the valve EGR.
12. Install and fasten the engine grounding lead on the housing of the transmission.
13. Install the generator lead and the starter lead on the corresponding terminals or in the
connectors.
Tip:
Make sure that all the leads are firmly plugged without grounding.
14. Plug the lead of the oil pressure warning unit into the warning unit connector.
15. Install the intake component and the intake hose of the engine on the intake manifold of the
engine; fasten the clamps.
Tip:
The intake pipe of the engine must be well sealed. The intake quality of the engine will directly affect its
service life.
16. Install the throttle body cable of the engine; make suitable adjustment.
Tip:
After installation, the accelerator cable must be debugged to avoid the over-large opening of the
accelerator while starting the engine.
17. Install the fuel feed pipe on the fuel inlet of the oil supply pump and install the clamp; install
the fuel return pipe and the clamp.
19. Connect the leads of all the sensors for the engine. Make sure that all the connectors are
firmly plugged.
20. Install the cooling line of the engine; fasten the hose and the clamps. Install the heater line;
fasten the clamp.
21. Fill the engine coolant to the standard level.
22. Fill an amount of engine lubricating oil. Ensure that lubricating oil is enough by observing
the dipstick.
23. Observe the connecting pieces around the engine so as to ensure firm and reliable
installation. Perform the engine test after making sure that the transmission is in the neutral
position.
24. Connect the battery leads.
Tip:
When installing the battery leads, install the positive terminal, and fix the bolt with sealing and insulation
treatment; then install the negative terminal, and fix the boil with sealing and insulation treatment.
25. Switch on the ignition switch, observe the display of instruments and make sure there are no
problems, and then start the engine. 01
Tip:
After the engine runs, observe the oil pressure gauge and water temperature gauge and make sure that 02
they are normal, enter the vehicle groove and observe whether there are water leakages, oil leakages
and air leakages around the engine, and shut down the engine for troubleshooting if any. Install other
03
accessories in order after making sure that the engine runs normally.
26. Install the cargo box.
27. Install the rear inspection cover of the engine, and then level the rear mat. 04
28. Install the supporting plate for the service brake control mechanism.
29. Install the transmission control mechanism and service brake control mechanism. 05
30. Install the driver’s and co-driver’s seats.
06
07
08
09
10
Instructions for Key Points

1. Instructions for Disconnecting and Connecting
Earth Wire of Battery
Instructions:
01 While removing the engine, the negative pole of the
battery shall be disconnected so as to ensure that the
02 engine is removed under power failure. On completion of
all the works, the negative pole shall be connected after
03 inspecting again carefully.
04
05 2. Instructions for Removing and Installing Fuel

pipes
06 Instructions:
While removing fuel pipes, the disconnected end shall be
07 capped with the fuel pipe cap. Because fuel is
inflammable, cigarettes, open fire, indicator lamps, arc
welding equipment and switches shall be away from the
08 working area which shall be provided with ventilation
equipment so as to reduce the possibility of serious
09 personal injury or even death.
10
3. Instructions for Removing and Installing Hoses,

Pipes and Blocking Components and Parts
Instructions:
Engine has too many lines and cable joints to distinguish
easily. For convenience of correct installation, the
positions of all the hoses, pipes, connecting rods and
electrical joints shall be marked by sticking labels while
removing and tied up on one side of the frame so as to
prevent blocking the operation. While installing, they shall
be installed in the correct positions according to the
indications on the labels.
4. Instructions for Protection measures for Engine

Instructions:
The engine generally can not operate normally and even
greatly damaged due to the existence of tiny foreign
matters inside. Thus, all the openings of the engine shall 01
be covered after disconnecting the pipe connected with
the engine so as to prevent dirt and debris from falling into 02
the engine.
03
04
05
06
5. Instructions for Removing and Installing Manners 07

of Engine
Instructions: 08
While removing the gasoline engine integrally, the engine
together with the transmission shall be removed from the 09
lower end of the beam by supports. While installing, the
engine together with the transmission shall be installed
10
from the lower end of the beam as well.
06-8 Complete Engine Set - Storage of Complete Engine Set
Storage of Complete Engine Set

Instructions:
• After storage for 24 months, the cooling system of the engine must be discharged, and the
engine must be washed with suitable solvent or hot and mild mineral oil. The washing steps
01
shall be repeated before reuse.
• Never remove the radiator pressure cap from a hot engine. The pressure cap can not be
02 removed until the temperature of coolant is reduced to 50℃ and below. Otherwise, the
high-temperature coolant or vapour will eject to result in personal injury.
03 • Coolant is toxic. Children and pets must be kept away from coolant. Coolant shall be
disposed in accordance with local applicable regulations for environmental protection if it is
04 not used any more.
1. Methods for Long-Term Storage of Engine
05 (a). Operate the engine at high idling until the coolant temperature reaches 71℃.
(b). Stall the engine.
(c). Discharge the engine oil.
06 (d). Install the drain plug.
(e). Apply preservative oil or equivalent so provide anti-rust protection for the long-term storage of
07 engine.
(f). Disconnect the fuel pipes for connecting fuel return pipes of the engine filter and the fuel injector.
08 (g). Apply preservative oil or equivalent.
(h). Fill one container with gasoline and fill another container with preservative oil. Arrange both fuel
09 pipes in the container filled with gasoline.
(i). Start the engine to operate for 25 minutes so as to distribute the preservative oil.
(j). Change the fuel supply pipe into the container filled with preservative oil when the engine operates
10
steadily.
(k). Operate the engine until the preservative oil flows out of the fuel return pipe of the fuel injector.
(l). “Stall” the engine.
(m). Connect the fuel pipe to the fuel return pipes of the fuel filter and the fuel injector.
(n). Drain the preservative oil from the oil sump of the engine oil plate and the Oil Filter.
(o). Evacuate engine coolant. Cover all the openings of the cooling system with plastic bowl-shaped
plug and adhesive tape.
(p). Remove the intake manifold and the exhaust manifold.
(q). Inject the preservative oil into the intake port and the exhaust port on the cylinder cover and the
manifolds.
(r). Remove the cover of the rocker arm chamber.
(s). Spray the preservative oil on the rocker arms, valve stems, valve springs, valve guide and tappets.
Apply preservative oil on the flywheels, flywheel housing and all other unpainted machined
surfaces.
(t). Install the cover of the rocker arm chamber, the intake manifold and the exhausted manifold.
(u). All the openings of parts and all the engine openings shall be covered with plastic bowl-shaped plug
and adhesive tape after removing the exhaust pipes so s to prevent dust and moisture from entering
into the engine.
Tip:
A label for warning shall be arranged on the engine, and the contents are as follows:
• Do not operate the engine.
• Do not drag the crank shaft.
• Engine has been treated with protection measures.
• Coolant has been drained.
• Date of treatment.
Complete Engine Set - Storage of Complete Engine Set 06-9
2. Cleaning of Engine after Long-Term Storage

(a). Washing the fuel system with cleaning gasoline until all the preservative oil is cleared.
(b). Remove the screw plug in the main oil gallery. Apply hot and mild mineral oil.
(c). Clear the preservative oil in the engine by washing.
(d). Drag the engine crankshaft for 3~4 circles in the process of washing. 01
(e). Fill the oil sump of the engine oil plate, the Oil Filter and the fuel filter.
(f). Fill coolant into the cooling system. 02
(g). Prefill engine oil into the lubrication system.
(h). Adjust the gap between the fuel injector and the valve.
03
(i). Screwing in the mounting bolts of the exhaust manifold.
04
05
06
07
08
09
10
- Remark -
01
02
03
04
05
06
07
08
09
10
Disassembly of Engine
Instructions for Disassembly ........................................07-1
Notes ........................................................................07-1 01
Ignition Coil Assembly..................................................07-2
Removal ...................................................................07-2 02
Exhaust Manifold Assembly .........................................07-4
Removal ...................................................................07-4 03
Oil Filter, Oil Pressure Sensor......................................07-6
Removal ...................................................................07-6
04
Generator ...................................................................07-7
Removal ..................................................................07-7
Fuel Rail Assembly, Thermostat ................................07-10 05
Removal .................................................................07-10
Intake Manifold, Inlet Hose.........................................07-12 06
Removal ................................................................07-12
Dipstick, Suspension Assembly .................................07-15 07
Removal ................................................................07-15
Water Pump Pulley, Crankshaft Pulley ......................07-17 08
Removal ................................................................07-17
Front Cover, Timing Belt ............................................07-19
09
Removal ................................................................07-19
Tensioner Pulley, Timing Crankshaft Pulley...............07-21
Removal ................................................................07-21 10
Camshaft Timing Gear, Rear Cover...........................07-23
Removal .................................................................07-23
Water Pump, Cylinder Head Cover ............................07-25
Removal ................................................................07-25
Cylinder Head, Rocker Arm, Valve, Camshaft ..........07-27
Removal ................................................................07-27
Flywheel, Engine Oil Plate .........................................07-31
Removal ................................................................07-31
Oil Filter, Oil pump .....................................................07-33
Removal .................................................................07-33
Rear End Cover of Crankshaft, Piston Assembly.......07-35
Removal ................................................................07-35
Crankshaft ................................................................07-39
Removal .................................................................07-39
01
02
03
04
05
06
07
08
09
10
Disassembly of Engine - Instructions for Disassembly 07-1
Instructions for Disassembly

Instructions
01
02
03
04
05
06
07
08
09
10
1. This Chapter provides a whole process for disassembling a complete set of gasoline engine from
top to bottom as well as from inside to outside. The diesel engine is assembled layer by layer, as
introduced by both pictures and text.
2. The gasoline engine disassembled in this Chapter is the LJ465Q3-1AE gasoline engine of Yuling
product series.
3. The engine assembly shall be place on the disassembly stand or on the clean and flat ground
before disassembling the engine. Necessary removal tools and professional containers or
environment for holding parts shall be ready.
4. The gasoline engine shall be disassembled in such a safe place that is far away from fire, children,
etc. as much as possible.
5. Before disassembling parts or components, such as unscrewing bolts and nuts, careful observation
shall be necessary. The knowledge obtained while disassembling is quite important for assembly.
6. Much more attention shall be paid to the components made of aluminum alloy, because they are
softer than those made of steel or cast iron, and their finished surfaces are so easy to scratch.
07-2 Disassembly of Engine - Ignition Coil Assembly

Removal
01 1. Remove Ignition Cable Components
(a). Pull out the ignition cable at the end of the spark
02 plug.
Tip:
03 The resistance at both ends of each ignition cable which
is of a damp type shall be no more than 25kΩ, otherwise
the ignition cable shall be replaced.
04
Caution:
Any ignition cable component shall be plugged by
05 holding its sheath without dragging or bending it,
otherwise its inside conductor will be damaged.
06
07
08
09
(b). Disconnect the ignition cable from the ignition coil.
10
(c). Pull the ignition cable out of clips one by one.

(d). Remove the ignition cable.
Caution:
The removed ignition cable shall be properly kept
and prevented from the contact with oil and
corrosive liquid such as corrosive acidic and
alkaline solutions so as to avoid damaging the
ignition cable.
Disassembly of Engine - Ignition Coil Assembly 07-3
2. Remove Ignition Coil

(a). Remove the fixing bolts of the ignition coil.
01
02
03
04
(b). Remove the ignition coil assembly.
Caution: 05
The removed ignition coil shall be put in a clean and
dry container separately. Any action that may 06
damage the ignition coil shall be prohibited, such as
knocking, collision, beating, etc.
07
08
09
3. Remove Ignition Coil Support
(a). Unscrew the fixing bolts for the ignition coil support 10
with a speeder wrench.
(b). Remove the ignition coil support .

07-4 Disassembly of Engine - Exhaust Manifold Assembly
Exhaust Manifold Assembly

Removal
01 1. Remove the Thermal Baffles of the Exhaust
Manifold
02 (a). Unscrew the fixing nuts for the thermal baffles of
the exhaust manifold and the fixing bolts for
03 connecting the upper and the lower thermal
baffles.
04
05
06
07
08
09 (b). Remove the upper lower thermal baffle of the

exhaust manifold.
10
(c). Remove the fixing bolts for the lower thermal baffle
of the exhaust manifold. Remove the lower thermal
baffle.
Disassembly of Engine - Exhaust Manifold Assembly 07-5
2. Remove Exhaust Manifold

(a). Remove the fixing nuts for the exhaust manifold.
01
02
03
04
05
06
(b). Remove the exhaust manifold. 07
08
09
10
(c). Remove the gasket and the thermal baffles of the

intake manifold
07-6 Disassembly of Engine - Oil Filter, Oil Pressure Warning Unit
Oil Filter, Oil Pressure Warning Unit

Removal
01 1. Remove Oil Filter
(a). Remove the Oil Filter with a wrench special for Oil
02 Filters.
Tip:
03 While removing the Oil Filter, the special wrench strap
shall be fixed at the hart part at the tail of the filter, the
filter shall be loosened by counterclockwise rotating the
04
special wrench with constant force manually, and the
loosened Oil Filter shall be removed by rotating
05 manually.
06
07
08
09 2. Remove Oil Pressure Warning Unit

(a). Remove the oil pressure warning unit with a
10 wrench.
Disassembly of Engine - Generator 07-7
Generator
Removal
1. Remove Generator Assembly 01
(a). Unscrew the adjusting screws for the upper
support of the generator. 02
03
04
05
06
07
08
(b). Push the generator to the engine to loosen the 09

generator. Remove the generator belt.
10
(c). Remove the clamp nuts for the fixing bolts at the
lower end of the generator. Pull out the fixing bolts.
07-8 Disassembly of Engine - Generator
(d). Remove the adjusting screws for the upper support

of the generator.
Caution:
While removing the last fixing bolt of the generator,
01 the generator shall be held up with the other hand
so as to avoid the personal injury of economic loss
02 due to the sudden free falling of the generator at the
moment of removing the fixing bolt.
03
04
05
06
07 (e). Remove the generator assembly.
08
09
10
2. Remove Upper Support of Generator

(a). Remove the two fixing bolts for the upper support
of the generator.
Disassembly of Engine - Generator 07-9
(b). Remove the upper support of the generator.
01
02
03
04
05
06
3. Remove Support of Air Conditioning 07

Compressor
(a). Remove the three fixing bolts for the support of the 08
air conditioning compressor.
09
10
(b). Remove the support of air conditioning

compressor.
07-10 Disassembly of Engine - Fuel Rail Assembly, Thermostat
Fuel Rail Assembly, Thermostat

Removal
01 1. Remove Fuel rail Assembly
(a). Pull out the vacuum connecting hose on the oil
02 pressure adjustor of the fuel rail assembly.
03
04
05
06
07
08
09 (b). Remove the two fixing bolts for the fuel rail
assembly.
10
(c). Remove the fuel rail assembly.

Tip:
This method is to remove the fuel injectors and the fuel
rail simultaneously. If it is difficult to pull out, each fuel
injector can be rotated manually to loosen the
contacted position with the intake manifold for the
convenience of pulling out.
Disassembly of Engine - Fuel Rail Assembly, Thermostat 07-11
2. Remove Thermostat
(a). Remove the two fixing bolts on the thermostat
cover.
01
02
03
04
05
06
(b). Remove the thermostat cover upwards. 07

Tip:
Because the contact surface of the thermostat shell 08
may be coated with sealant, the hard part of the
thermostat cover shall be slightly beaten by a rubber 09
hammer to loosen it.
10
(c). Pull out the thermostat.

07-12 Disassembly of Engine - Intake Manifold, Inlet Hose
Intake Manifold, Inlet Hose

Removal
01 1. Remove Intake Manifold
(a). Disconnect the crankcase breather from the
02 cylinder head cover.
• Clinch the clips with pliers to open the clips.
03 • Pull out the hose.
04
05
06
07
08
09 (b). Disconnect the return water rubber hose from the

inlet hose assembly.
10 • Clinch the clips with pliers to open the clips.
• Pull out the hose.
(c). Remove the fixing bolts for supports from the lower
end of the intake manifold.
Caution:
Before removing the fixing bolts for supports from
the lower end of the intake manifold, the engine
shall be fixed by arranging a wood block or
equivalent at the bottom of the removing the fixing
bolts for supports from the lower end of the intake
manifold.
Disassembly of Engine - Intake Manifold, Inlet Hose 07-13
(d). Remove the fixing bolts and nuts for connecting the
intake manifold with the cylinder head.
01
02
03
04
05
06
(e). Remove the intake manifold assembly. 07

Tip:
Because the contact surface of the intake manifold with 08
the cylinder head may be coated with sealant, intake
manifold shall be slightly shaken to loosen the adhesive 09
part with the contact surface, and then the intake
manifold can be removed. 10
2. Remove the Inlet Hose Assembly

(a). Remove the two fixing bolts for the inlet hose.
07-14 Disassembly of Engine - Intake Manifold, Inlet Hose
(b). Remove the inlet hose assembly from the cylinder.
01
02
03
04
05
06
07
08
09
10
Disassembly of Engine - Dipstick, Suspension Assembly 07-15
Dipstick, Suspension Assembly

Removal
1. Remove Dipstick Assembly 01
(a). Remove the dipstick.
02
03
04
05
06
07
08
(b). Pull out the guide pipe of the dipstick with pliers. 09
Tip:
The guide pipe of the dipstick is inlaid in the mounting 10
hole of the cylinder. While removing, the middle of the
guide pipe can be fixed by the pliers and then taken out
by beating the root of the pliers with a hammer
upwards.
2. Remove Right Suspension Assembly

(a). Remove the two fixing bolts for the right
suspension assembly.
07-16 Disassembly of Engine - Dipstick, Suspension Assembly
(b). Remove the right suspension assembly.

Tip:
While removing the bolts, the suspension assembly
shall be seized by one hand as much as possible so as
01 to avoid personal injury due to its free falling.
02
03
04
05
06
07 3. Remove Left Suspension Assembly

(a). Remove the two fixing bolts for the left suspension
08 assembly.
09
10
(b). Remove the right suspension assembly.

Disassembly of Engine - Water Pump Pulley, Crankshaft Pulley 07-17
Water Pump Pulley, Crankshaft Pulley

Removal
1. Remove Water Pump Pulley 01
(a). Remove the fixing bolts for the water pump pulley.
Tip: 02
While removing the water pump pulley, a rubber rod or
wood rod can be clamped between the water pump 03
pulley and the crankshaft pulley so as to avoid the
rotation of the pulley with the removed bolts.
04
05
06
07
08
(b). Remove the water pump pulley. 09
10
2. Remove Crankshaft Pulley

(a). Install the flywheel locator in a thorough suitable
hole. Fasten the fixing nuts.
Tip:
The flywheel locator is installed for avoid removing
difficulty caused by the rotation of the crankshaft along
with the wrench while removing the fixing bolts for the
crankshaft pulley
07-18 Disassembly of Engine - Water Pump Pulley, Crankshaft Pulley
(b). Remove the central fixing bolt for the crankshaft

pulley.
01
02
03
04
05
06
07 (e). Remove the crankshaft pulley.

Tip:
08 The engine crankshaft is more convenient to take out. If
it can not be pulled out with both hands, the hard
09 position of the crankshaft pulley can be slightly beaten
by a rubber hammer or copper rod to loosen it, so that it
10 can be taken out conveniently.
Disassembly of Engine - Front Cover, Timing Belt 07-19
Front Cover, Timing Belt

Removal
1. Remove Front Cover 01
(a). Remove the peripheral fixing bolts of the front
cover in order. 02
03
04
05
06
07
08
(b). Remove the front cover. 09

Tip:
The front cover shall not be taken out directly so as to 10
avoid damaging the sealing rubber gasket of the front
cover. When the front cover is taken out for 1 ~ 2cm, it
shall be observed whether the sealing rubber gasket
between the front cover and the rear cover is partially
adhesive to the front cover and the rear cover, and it
shall be shoveled with a scraper in such case.
2. Remove Timing Pulley

(a). Remove the fixing bolts for the camshaft timing
gears with a wrench.
Tip:
The camshaft timing gears shall be removed after
removing the belt. Otherwise, the gears will rotate along
with removing the fixing bolts. It is inconvenient for
removing and can result in damage to valves and the
piston. Therefore, the fixing bolts for the camshaft
timing gears shall be unscrewed before removing the
timing pulley.
07-20 Disassembly of Engine - Front Cover, Timing Belt
(b). Unscrew the adjusting screws of the tensioner

pulley.
01
02
03
04
05
06
07 (c). Move the tensioner pulley with a screwdriver or

equivalent to trip off the spring hook and loosen the
08 timing belt.
09
10
(d). Remove the timing belt.

Disassembly of Engine - Tensioner Pulley, Crankshaft Timing Pulley 07-21
Tensioner Pulley, Crankshaft Timing Pulley

Removal
1. Remove Tensioner Pulley 01
(a). Remove the torsion spring fixing bolts of the
tensioner pulley. 02
03
04
05
06
07
08
(b). Remove the tensioner pulley. 09
10
2. Remove Crankshaft Timing Pulley

(a). Pull out the crankshaft timing pulley with a special
puller.
Tip:
The crankshaft timing pulley is generally easier to
remove.
07-22 Disassembly of Engine - Tensioner Pulley, Crankshaft Timing Pulley
(b). Remove the crankshaft timing pulley.
01
02
03
04
05
06
07
08
09
10
Disassembly of Engine - Camshaft Timing Gear, Rear Cover 07-23
Camshaft Timing Gear, Rear Cover

Removal
1. Remove Camshaft Timing Gear 01
(a). Remove the fixing bolts for the camshaft.
Tip: 02
If the fixing bolts are not unscrewed before removing
the timing belt, the camshaft timing gear shall be fixed 03
with a special tool. It must be ensure that the camshaft
gear will not rotate along with it so as to avoid damage
04
to valves or pistons.
05
06
07
08
(b). Remove the camshaft timing gear. 09
10
2. Remove Rear Cover

(a). Remove the fixing bolts for the rear cover.
07-24 Disassembly of Engine - Camshaft Timing Gear, Rear Cover
(b). Remove the rear cover.
01
02
03
04
05
06
07
08
09
10
Disassembly of Engine - Water Pump, Cylinder Head Cover 07-25
Water Pump, Cylinder Head Cover

Removal
1. Remove Water Pump Assembly 01
(a). Remove the fixing bolts for the water pump.
02
03
04
05
06
07
08
(b). Remove water pump assembly. 09

Tip:
If the water pump assembly is in a closer connection 10
with the crankcase, it is convenient to take it out by
beating with a rubber hammer but never with an iron
hammer.
2. Remove Cylinder Head Cover

(a). Screw out the filler cap.
Tip:
The filler cap shall be turned over with the inside facing
upwards.
07-26 Disassembly of Engine - Water Pump, Cylinder Head Cover
(b). Remove the fixing bolts for the cylinder head cover
with a speeder wrench.
01
02
03
04
05
06
07 (c). Remove the cylinder head cover.

Tip:
08 The removed cylinder head cover shall be arranged by
turning over. Never make the gasket side of the cylinder
09 head cover faces downwards.
10
Disassembly of Engine - Cylinder Head, Rocker Arm, Valve, Camshaft 07-27
Cylinder Head, Rocker Arm, Valve, Camshaft

Removal
1. Remove Cylinder Head Assembly 01
(a). Remove the bolts for the cylinder head.
Tip: 02
It is recommended to unscrew the 10 bolts one by one
symmetrically and crossly and then screw out each bolt. 03
04
05
06
07
08
Caution: 09
It is recommended to remove the bolts for the
cylinder head according to the order shown in the 10
left picture.
(b). Remove the cylinder head assembly.

Tip:
The cylinder head to be repaired shall be disassembled
according to specific requirements. Otherwise, the
cylinder head will not be disassembled.
07-28 Disassembly of Engine - Cylinder Head, Rocker Arm, Valve, Camshaft
2. Remove Rocker Arm Component

(a). Fully loosen the 8 adjusting screws for the rocker
arm.
01
02
03
04
05
06
07 (b). Remove the 10 locking screws for the rocker arm

shaft.
08
09
10
(c). Pull out the rocker arm shaft. Remove the rocker
arm component and the rocker arm shaft spring.
Tip:
The other end of the rocker arm shaft shall be slightly
rushed out with a punch, and then the rocker arm shaft
shall be rotated to pull out. The rocker arms and the
rocker arm springs shall be removed in order, and the
rocker arms shall be marked with assembling labels.
Disassembly of Engine - Cylinder Head, Rocker Arm, Valve, Camshaft 07-29
3. Remove Valve Components

(a). Compress valve springs with a valve spring
compressor.
(b). Remove the valve components.
01
02
03
04
05
06
4. Remove Camshaft Components 07

(a). Remove the fixing bolts for the rear end cover of
the cylinder head. 08
09
10
(b). Remove the rear end cover of the cylinder head.

07-30 Disassembly of Engine - Cylinder Head, Rocker Arm, Valve, Camshaft
(c). Remove cross recessed raised countersunk head

screws for the thrust plate of the camshaft with a
cross screwdriver.
01
02
03
04
05
06
07 (d). Pull out the camshaft towards the rear end.

Tip:
08 The camshaft shall be taken out quite carefully by
rotating and avoiding collision.
09
10
Disassembly of Engine - Flywheel, Oil Pan 07-31
Flywheel, Oil Pan

Removal
1. Remove Flywheel 01
(a). Remove the six fixing bolts for the flywheel.
02
03
04
05
06
07
08
(b). Remove the flywheel locator. 09
10
(c). Remove the flywheel assembly.

07-32 Disassembly of Engine - Flywheel, Oil Pan
2. Remove Oil pan

(a). Remove the fixing bolts for the oil pan.
01
02
03
04
05
06
07 (b). Shake the oil pan to loose with a rubber hammer.
08
09
10
(c). Remove the oil pan.

Disassembly of Engine - Oil Filter, Oil Pump 07-33
Oil Filter, Oil Pump

Removal
1. Remove Oil Filter Assembly 01
(a). Remove the two fixing bolts for the Oil Filter.
02
03
04
05
06
07
08
(b). Remove the oil filter assembly. 09
10
2. Remove Oil Pump Assembly

(a). Remove the fixing bolts for the oil pump assembly.
07-34 Disassembly of Engine - Oil Filter, Oil Pump
(b). Remove the oil pump assembly.
01
02
03
04
05
06
07
08
09
10
Disassembly of Engine - Rear End Cover of Crankshaft, Piston Assembly 07-35
Rear End Cover of Crankshaft, Piston Assembly

Removal
1. Remove Rear End Cover of Crankshaft 01
(a). Remove the 6 fixing bolts for the rear end cover of
the crankshaft. 02
03
04
05
06
07
08
(b). Remove the rear end cover of the crankshaft. 09
10
2. Remove Piston Assembly

(a). Rotate the crankshaft until the piston assembly to
be removed reaches the bottom dead center, i.e.,
expose the piston connecting rod vertically for
convenience of removal.
07-36 Disassembly of Engine - Rear End Cover of Crankshaft, Piston Assembly
(b). Remove the nuts for the piston connecting rod.
01
02
03
04
05
06
07 (c). Remove the connecting rod bearing shells. Mark

each connecting rod bearing shell on its movable
08 lug according to the cylinder number.
09
10
(d). Clear the carbon deposit in the piston cylinder.

Caution:
• The cleaning by solvents and acid or alkaline
substances shall be subject to the usage
proposal from the manufacturer. Goggles and
protective clothing shall be worn to avoid
personal injuries.
• Some solvents are inflammable and toxic.
Before use, carefully read the manual of the
manufacturer.
Disassembly of Engine - Rear End Cover of Crankshaft, Piston Assembly 07-37
(e). Push out the piston assembly.

Tip:
The piston assembly shall be pushed out with a
substance made of wood or rubber. Never use those
made of metal to avoid damaging the end surfaces of 01
the connecting rod.
02
03
04
05
06
(f). Take out the piston assembly from the other side. 07
08
09
10
(g). Assemble a set of parts of piston assembly and

mark it with cylinder number.
Tip:
If these parts will be used continuously, the piston and
the connecting rod assembly must be installed in the
same cylinder gasket for installation, and the ground
mating faces must be ensured to be in correct fit.
07-38 Disassembly of Engine - Rear End Cover of Crankshaft, Piston Assembly
(h). Rotate the crankshaft to expose the connecting rod

nuts of other two cylinders. Remove the remaining
piston assembly according to the above methods.
Tip:
01 If the piston assembly is not used at once, the
connecting rod and the piston assembly shall be put in
02 the container to avoid damage.
03
04
05
06
07
08
09
10
Disassembly of Engine - Crankshaft 07-39
Crankshaft
Removal
1. Remove Crankshaft Assembly 01
(a). Unscrew the bolts for the main bearing cover one
by one. 02
Tip:
The bolts shall be unscrewed one by one in a cross 03
manner. But never remove them.
04
05
06
07
08
Caution: 09
The removing operation shall be in accordance with
the removal order shown in the left picture. 10
(b). Remove the main bearing cover. Arrange them in

order.
Tip:
• The main bearing cover shall be shaken by seizing
the bolts with both hands or vibrated to loose by
using a rubber hammer, and then taken out.
• Each main bearing cover shall have a lable for
assistance of memory.
07-40 Disassembly of Engine - Crankshaft
(c). Remove the main bearing shell.

Tip:
Never forget to remove the thrust washers of the
crankshaft. Remember to record the installation
01 positions and the front and back faces to avoid mistake
in installation.
02
03
04
05
06
07 (c). Each main bearing shell shall be marked on its

movable lug according to the cylinder number.
08
09
10
(d). Take out the crankshaft assembly.

Tip:
The heavier component or assembly shall be lifted
under the assistance of others or by using suitable
hoisting equipment so as to avoid serious personal
injury.
Disassembly of Engine - Crankshaft 07-41
(e). Take out the upper shells of the main bearing shell.
Tip:
The upper shells shall be taken out one by one and
marked with the cylinder number on the movable lugs.
Never forget to remove the thrust washers of the 01
crankshaft. Remember to record the mounting positions
and the front and back faces to avoid mistake in 02
installation.
03
04
05
06
07
08
09
10
- Memo -
01
02
03
04
05
06
07
08
09
10
Assembly of Engine
Instructions for Assembly .............................................08-1
Instruction .................................................................08-1 01
Crankshaft....................................................................08-2
Installation ................................................................08-2 02
Piston Assembly...........................................................08-6
Installation ................................................................08-6 03
Rear End Cover of Crankshaft, Oil Pump ..................08-12
Installation ..............................................................08-12
04
Oil Filter, Oil Pan ........................................................08-14
Installation ..............................................................08-14
Flywheel, Camshaft, Valve.........................................08-16 05
Installation ..............................................................08-16
Rocker Arm, Cylinder Head .......................................08-21 06
Installation ..............................................................08-21
Cylinder Head Cover, Water Pump ............................08-24 07
Installation ..............................................................08-24
Rear Cover, Camshaft Timing Gear...........................08-26 08
Installation ..............................................................08-26
Crankshaft Timing Pulley, Tensioner Pulley...............08-28
09
Installation ..............................................................08-28
Timing Belt, Front Cover ............................................08-30
Installation ..............................................................08-30 10
Crankshaft Pulley, Water Pump Pulley ......................08-33
Installation ..............................................................08-33
Suspension Assembly, Dipstick .................................08-35
Installation ..............................................................08-35
Inlet Hose, Intake Manifold.........................................08-37
Installation ..............................................................08-37
Thermostat, Fuel Rail Assembly ................................08-40
Installation ..............................................................08-40
Generator ...................................................................08-42
Installation ..............................................................08-42
Oil Pressure Warning Unit, Oil Filter ..........................08-45
Installation ..............................................................08-45
Exhaust Manifold........................................................08-46
Installation ..............................................................08-46
Ignition Coil Assembly................................................08-48
Installation ..............................................................08-48
01
02
03
04
05
06
07
08
09
10
Assembly of Engine - Instructions for Assembly 08-1
Instructions for Assembly

Instructions
01
02
03
04
05
06
07
08
09
10
1. This Chapter provides a whole process for assembling a complete set of gasoline engine from top to
bottom as well as from inside to outside. The gasoline engine is assembled layer by layer, as
introduced by both pictures and text.
2. The gasoline engine assembled in this Chapter is the LJ465Q3-1AE gasoline engine of Yuling
product series.
3. The diesel engine shall be assembled in such a safe place that is far away from fire, children, etc. as
much as possible.
4. The original components shall be assembled in the original positions before disassembly, without
neglecting any parts.
5. All the parts and components to be assembled must be clean enough.
6. Before assembly, the components with sliding and rubbing surfaces for the engine shall be applied
with lubricating oil.
7. Sealant shall be prepared before assembly. It shall be applied where indicated to ensure no
leakage.
8. The gaps where specific requirements are needed shall be inspected in the process of assembly.
9. Cylinder gaskets, O-rings and various gaskets must be in perfect condition; otherwise, they shall be
replaced by spare parts.
10. A torque wrench and the values indicated in Chapter 3 Maintenance Specification shall be used for
the main components (bolts and nuts of main parts) and other parts of the engine with indicated
screwing torque.
11. The markers shall be aligned for the marked parts.
12. Combined components such as crankshaft, bushes, piston, connecting rod, etc. mustn’t be
mistaken, and each part shall be put in its original position.
08-2 Assembly of Engine - Crankshaft
Crankshaft
Installation
01 1. Install Crankshaft
(a). Install the upper shells of the main bearing shells in
02 the corresponding positions.
Tip:
03 The upper shells of the main bearing shells shall be
installed in the corresponding positions carefully in
order. Make sure that the back of each bearing shell is
04
clean without scrap, the upper shell of each main
bearing shell is in the center of the shell groove, and the
05 upper end surfaces shall be parallel. Appropriate
amount of engine oil or equivalent shall be applied on
06 the inner side of the arched surface of each bearing
shell.
07
08
09 Caution:
Make sure that the locating lugs of the bearing
10 shells are aligned with the locating grooves on the
cylinder saddle of the main bearing shells while
installing.
(b). Install thrust plate of crankshaft.

Caution:
While installing, the oil groove of the thrust washer
shall face outwards.
Assembly of Engine - Crankshaft 08-3
(c). Engine oil or equivalent lubricating oil shall be

dropped on the inner side of the main bearing
shells.
Caution:
Never drop engine oil on the outer side of any main 01
bearing shell.
02
03
04
05
06
(d). Install the crankshaft assembly in the 07

corresponding position.
Caution: 08
• The heavier component or assembly shall be
lifted under the assistance of others or by 09
using suitable hoisting equipment so as to
avoid serious personal injury. 10
• The crankshaft shall be installed carefully so as
to avoid damaging the main bearing of the
crankshaft, especially the thrust/main bearing
journal. The service life of the engine will be
shortened once the crankshaft is damaged.
(e). Drop clean engine oil or equivalent lubricating oil

on the main bearing journal of the installed
crankshaft.
08-4 Assembly of Engine - Crankshaft
(f). Apply engine oil on the lower shell of the main

bearing shell. Install the lower shell on the main
bearing cover.
Tip:
01 Enable the lower shell of the main bearing shell to slide
into the main bearing shell cover from on side. Planish
02 the end surfaces.
03
04
Caution:
05 Make sure that the locating lug of the bearing shell
is aligned with the locating groove on the main
06 bearing cover while installing.
07
08
09
(g). Install the main bearing covers in order.
10 Tip:
• While installing the rear main bearing cover,
attention shall be paid to that the thrust washer of
the crankshaft may fall off.
• The main bearing covers shall be installed in the
original positions without any mistake.
Tip:
All the main bearing covers of the crankshaft shall be
marked with numbers for identification and shall be
installed in order without confused assembly，
Caution:
While arranging the main bearing covers of the
crankshaft on the main bearing seats on the
crankcase, the arrow on each cover shall point at
the front end (the direction of pulleys).
Assembly of Engine - Crankshaft 08-5
(h). Arrange the bolts for the main bearing cover in the
mounting holes in order. Screw them up slightly
with hands.
Tip:
Drop an appropriate amount of engine oil on the 01
threads of the bolts for the main bearing cover.
02
03
04
05
06
(i). Screw up the main bearing bolts according to 07

certain orders and torques.
Torque: 42.17~47.07N·m 08
09
10
Tip:
• The bolts shall not be screwed up by one time but
shall be screwed a little until reach the specified
torque gradually.
• The main bearing bolts must be screwed up in a
certain order (as shown in the left picture).
Tip:
The installed crankshaft shall be rotated for several circles to check whether the rotation is smooth and
flexible.
08-6 Assembly of Engine - Piston Assembly
Piston Assembly
Installation
01 1. Install Piston Assembly
(a). Install the connecting rod bolts on the connecting
02 rod.
03
04
05
06
07
08
09 (b). Install the upper shell of the connecting rod bearing

shell for the piston.
10 Tip:
Before assembly, the cylinder and all the parts must be
kept clean. The connecting rod and the bearing shell
shall be cleaned with a piece of clean cloth without
fluffing.
Caution:
Make sure that the back sides of the connecting rod
and the connecting rod bearing are clean without
any scrap. Never lubricate the back side of any
connecting rod bearing.
Caution:
Make sure that the locating lug of the bearing shell
is aligned with the locating groove on the
connecting rod while installing.
Assembly of Engine - Piston Assembly 08-7
(c). Drop clean engine oil or equivalent lubricating oil

on the inner side of the bearing shell.
01
02
03
04
05
06
(d). Lubricate the piston ring and the piston skirt with 07
clean engine oil.
08
09
10
(e). Rotate the piston rings and adjust the position of

their openings as shown in the picture.
Tip:
The opening of each piston ring shall not be aligned
with the opening of the piston pin or other piston rings.
The piston rings can not be correctly sealed due to the
incorrect positions of their openings.
(f). Compress the piston ring into the working position

with the piston ring compressor.
Tip:
An annular cylinder can be self-made with an iron sheet
in case of no special tool.
(g). Rotate the crankshaft to make the journal of the

connecting rod to be installed in the position of the
bottom dead center.
01
02
03
04
05
06
07 (h). Apply a thin layer of clean engine oil on each

cylinder wall.
08
09
10
(i). Insert the connecting rod into each cylinder hole

until the piston ring compressor touches the top of
the cylinder.
Tip:
The arrow on top of the piston shall be aligned to point
at the front of the engine. The long end of the
connecting rod and the notch on the piston skirt shall be
on the exhaust side of the. If not, it shall be inspected 01
whether the piston is correctly installed on the
connecting rod. 02
Caution:
The engine will be seriously damaged if it is not 03
operated in accordance with this step.
04
05
06
(j). Jack the cylinder with the piston ring compressor. 07

Pass the piston through the piston ring compressor
and push it into the cylinder hole. 08
Caution:
If the piston can not move freely, it shall be 09
removed to check whether the piston ring is broken
or damaged. 10
(k). Install the lower shell of the bearing shell of the

connecting rod on the bearing shell cover of the
connecting rod.
Caution:
• Make sure that the back sides of the
connecting rod and the connecting rod bearing
are clean without any scrap. Never lubricate the
back side of any connecting rod bearing.
• If a new bearing is not used, the old one must
be installed in the same connecting rod cover
which is used while installing.
Caution:
Make sure that the locating lug of the bearing shell
is aligned with the locating groove on the
connecting rod cover while installing.
(l). Lubricate the inner side of the lower shell of the

bearing shell of the connecting rod with clean
engine oil.
01
02
03
04
(m). Install the connecting rod cover on the
05 corresponding journal of the crankshaft.
06
07
08
09
10
Caution:
The arrow on the upper end surface of the
connecting rod cover must point at the rear end
(mounting end of flywheels).
(n). Install the connecting rod nuts and screw them up

with a torque wrench in alternation by several times
according to the angular tightening method.
Torque: 27.46~31.38N·m
Tip: 01
The connecting rod nuts shall be gradually screwed up
in pairs and in alternation. 02
(o). Measure the backlash between the connecting rod
body and the crankshaft. 03
Tip:
The backlash between the connecting rod and the
crankshaft shall be measured but not that between the 04
connecting rod cover and the crankshaft.
05
06
Tip: 07
If the piston, crankshaft, connecting rod or cylinder is
changed/replaced, it is necessary to measure the 08
extrusion of the piston from the cylinder combustion
front. The steps are as follows: 09
• Install a dial indicator on the cylinder head, and
zero it. 10
• Move the dial indicator over the piston top to
eliminate all sidewise movements.
• Rotate the crankshaft clockwise and
counterclockwise, observe the maximum reading
of the dial indicator, and record the measurement
result. Judge the result.
08-12 Assembly of Engine - Rear End Cover of Crankshaft, Oil Pump
Rear End Cover of Crankshaft, Oil Pump

Installation
01 1. Install Rear End Cover of Crankshaft
(a). Arrange the rear end cover of the crankshaft in the
02 mounting position.
Tip:
03 The rear end cover must be installed by using a new
gasket, and the removed one shall never be used.
Before installation, the connecting surface between the
04
gasket and the crankcase shall be evenly applied with
HZ-1 oil-resistant RTV sealant, and the oil seal part
05 shall be applied with IL-2 lithium base grease.
06
07
08
09 (b). Install the fixing bolts for the rear end cover of the
crankshaft and screw them up in the manner of
10 diagonal screwing.
(c). Cut off the protruded gasket with a scraper knife.

Tip:
The gasket is usually protruded after installing the rear
end cover of the crankshaft on the crankcase.
Assembly of Engine - Rear End Cover of Crankshaft, Oil Pump 08-13
2. Install Oil Pump

(a). Arrange the oil pump assembly in the mounting
position.
Tip:
The oil pump must be installed by using a new gasket, 01
and the removed one shall never be used. Before
installation, both sides of the gasket shall be evenly 02
applied with HZ-1 oil-resistant RTV sealant, and the
front oil seal part of the crankshaft shall be applied with 03
IL-2 lithium base grease.
04
05
06
(b). Install the fixing bolts for the oil pump and screw 07
them up in the manner of diagonal screwing.
08
09
10
(c). Cut off the protruded gasket with a scraper knife.

Tip:
After the rear end cover of the crankshaft is installed on
the crankcase, the gasket is usually protruded and shall
be scraped.
08-14 Assembly of Engine - Oil Filter, Oil Pan
Oil Filter, Oil Pan

Installation
01 1. Install Oil Filter
(a). Install the O-ring of the Oil Filter.
02 Tip:
It is easy to forget to install an O-ring here, so it is
03 necessary to check while installing. The Oil Filter
assembly can not play its role if the O-ring is not
installed.
04
05
06
07
08
09 (b). Arrange the Oil Filter in the mounting position.

Screw the fixing bolts manually.
10
(c). Screw up two fixing bolts for the oil filter with a
wretch.
Tip:
The fixing nuts and bolts for the oil pump assembly
shall be screwed up gradually in alternation.
Assembly of Engine - Oil Filter, Oil Pan 08-15
2. Install Oil Pan

(a). Close the oil pan.
Tip:
While installing the oil pan, a new gasket shall be
replaced, and suitable sealant shall be applied to the 01
connecting surface.
02
03
04
05
06
(b). Install the fixing bolts for the oil pan. 07

Tip:
All the fixing bolts for the oil pan shall be screwed 08
manually at first without missing any one. The thread
and the sealing surface of the drain plug shall be 09
cleaned and inspected.
Caution: 10
Not any bolt shall be over-screwed by one time.
Tip:
All the bolts shall be screwed up according to the order
shown in the left picture.
Torque: 3.9~4.9N·m
08-16 Assembly of Engine - Flywheel, Camshaft, Valve
Flywheel, Camshaft, Valve

Installation
01 1. Install Flywheel
(a). Confirm whether the flywheel dowel pin is installed
02 on the crankshaft. If not, install the dowel pin firstly.
03
04
05
06
07
08
09 (b). Apply grease in the hole between the input

crankshaft bearing and the oil seal.
10 Tip:
The filling volume of the grease shall be about 60% of
the hole volume.
(c). Arrange the flywheel assembly in the mounting

position.
Tip:
Screw the fixing bolts for the flywheel manually.
Assembly of Engine - Flywheel, Camshaft, Valve 08-17
(d). Install the flywheel locator.

Tip:
While installing the flywheel locator, it is recommended
to rotate the crankshaft to make the four piston
assemblies in the center of the cylinders, which is 01
convenient for the successive installation.
02
03
04
05
06
(e). Fasten the fixing bolts for the flywheel. 07

Torque: 39.23~49.03N·m
08
09
10
2. Install Camshaft
(a). Drop clean engine oil or equivalent lubricating oil
on the journal of the camshaft.
(b). Place the camshaft.

Tip:
Insert the front end of the camshaft into the rear end of
the cylinder head towards its front end.
01
02
03
04
05
06
07 (c). Install the camshaft thrust plate.

Tip:
08 Install the camshaft in a suitable position. Install the
camshaft thrust plate with one hand, and rotate the
09 camshaft with the other hand simultaneously to
confirm that the camshaft can rotate smoothly.
10
(d). Install and fasten the fixing bolts for the camshaft
thrust plate.
Assembly of Engine - Flywheel, Camshaft, Valve 08-19
(e). Close the rear end cover of the cylinder head.

Tip:
Replace a new gasket.
01
02
03
04
05
06
(f). Install and fasten the fixing bolts for the rear end 07
cover of the cylinder head.
08
09
10
2. Install Valves
(a). Lubricate the holes of all valve guides and valve
stems by using clean engine oil.
Tip:
The valve guides will be abraded quite early if the
valve guides and valve stems are not lubricated.
Caution:
Distinguish the intake valve from the exhaust valve
according to the differences in the diameter at the
big end and the shape at the disk end. The disk
end surface of the intake valve is in the shape of a
concave circular arc, and that of the exhaust valve
is flat.
(b). Put the valve stem in the mounting position.

Tip:
If the valve to be installed is the same as the removed
one, the valve shall be ensured to be installed in the
01 same position where the former one is removed. A
new valve oil seal shall be replaced at the same time.
02
03
04
05
06
07 (c). Install the valve spring base, valve spring and

valve spring retainer.
08 Tip:
Each valve spring has a big-interval end and a
09 small-interval end. The small-interval end shall be
arranged at the bottom while installing the spring.
10 Caution:
The removed valve oil seal must be replaced. The
specific methods for replacement shall refer to
Chapter 9 Mechanical System, Valve.
(d). Install the tapered cotter.

Tip:
Compress the valve spring with a valve spring
compressor to expose the mounting position of
tapered cotter. Put in the tapered cotter and release
the valve spring. Beat the valve spring retainer with a
valve plastic hammer as soon as the valve assembly is
locked by the tapered cotter. Make sure that the valve
lock is correctly installed by knocking with the hammer.
Caution:
Goggles shall be worn to reduce the possibility of
personal injury. If the lock clamp is not correctly
installed, it will burst out while knocking the valve
spring retainer with the plastic hammer.
Assembly of Engine - Rocker Arm, Cylinder Head 08-21
Rocker Arm, Cylinder Head

Installation
1. Install Rocker Arm Assembly 01
(a). Drop clean engine oil or equivalent lubricating oil
on the rocker arm shaft. 02
03
04
05
06
(b). Install the rocker arm shaft cylinder head by
passing through the rocker arm hole.
07
Caution:
While installing rocker arm shaft, fully unscrew but
never remove the valve adjusting screws. 08
09
10
Tip:
It is unnecessary to distinguish the same two rocker
Exhaust side
arm shafts, but each rocker arm shaft can only adopt
one assembling position. The specific mounting
position is shown in the left picture.
Front end Rear end
Intake side
Caution:
The positions of the rocker arm and the rocker arm
spring installed on the rocker arm must be correct
as the mounting positions shown in the left
Front end
picture.
Rear end
08-22 Assembly of Engine - Rocker Arm, Cylinder Head
(c). Install the locking screws for the rocker arm shaft.
Tip:
All the locking screws shall be screwed up one by one
from the middle to both sides.
01
02
03
04
05
06
07 2. Install Cylinder Head

(a). Rotate the crankshaft to ensure the four pistons to
08 locate in the center of the cylinder at the same
time.
09 Tip:
While installing flywheels, this step can be omitted if
10 the locator is used; if not, this step is very important.
Because the positions of the pistons and the valves
are not fixed while installing the cylinder head, some
valves will touch the top of pistons to result in the
damage of valves or pistons.
(b). Install the gasket for the cylinder head in position.

Tip:
Make sure that the gasket is correctly aligned with the
holes on the crankcase. If not, the crankcase may be
damaged.
Assembly of Engine - Rocker Arm, Cylinder Head 08-23
(c). Put the cylinder head assembly on the crankcase

carefully and align it.
Tip:
The heavier component or assembly shall be lifted
under the assistance of others so as to avoid serious 01
personal injury.
02
03
04
05
06
(d). Put in the fixing bolts for the cylinder head and 07
screw them up.
Torque: 53.94~58.84N·m 08
Tip:
Lubricate the threads of the mounting bolts and the 09
bottom of the tip of the bolts for the cylinder head with
clean engine oil. 10
Caution:
The bolts for the cylinder head shall be gradually
screwed up until reaching the specified value by
several times according to the order shown in the
left picture.
08-24 Assembly of Engine - Cylinder Head Cover, Water Pump
Cylinder Head Cover, Water Pump

Installation
01 1. Install Cylinder Head Cover
(a). Close the cylinder head cover.
02 Tip:
Any aged or corroded gasket for the cylinder head
03 cover shall be replaced.
04
05
06
07
08
09 (b). Install and fasten the fixing bolts for the cylinder
head cover.
10 Tip:
While installing the fixing bolts for the cylinder head
cover, never forget the clips and other components
and parts to be installed together with the bolts.
(c). Check and install the filler cap.

Assembly of Engine - Cylinder Head Cover, Water Pump 08-25
2. Install Water Pump Assembly

(a). Put the water pump assembly in the mounting
position.
Tip:
While installing the water pump, the gasket of the 01
water pump shall be installed firstly and applied with
sealant, and the fixing bolts for the water pump 02
assembly shall be applied with GY-340 anaerobic
adhesive. At the same time, the spongy cushion of the 03
rear cover, etc. shall be installed.
04
05
06
(b). Install and fasten the fixing bolts for the water 07
pump assembly.
Tip: 08
All the bolts shall be fastened diagonally one by one.
09
10
08-26 Assembly of Engine - Rear cover, Camshaft Timing Gear
Rear cover, Camshaft Timing Gear

Installation
01 1. Install Rear Cover
(a). Put the rear cover in the mounting position and
02 align it with the mounting hole.
03
04
05
06
07
08
09 (b). Install and fasten the fixing bolts for the rear
cover.
10
2. Install Camshaft Timing Gear

(a). Put the camshaft timing gear in the mounting
position.
Tip:
While installing, the key groove on the camshaft timing
gear shall be aligned with the tip of the camshaft.
Assembly of Engine - Rear cover, Camshaft Timing Gear 08-27
Tip:
There are labels of two bulged arrows and one dot on
each side of the camshaft timing gear for confirm
whether the camshaft timing gear is installed in
position. While installing, the side with labels shall face 01
outwards, and the labels shall be aligned with the key
groove of the camshaft. 02
03
04
05
06
(b). Install and fasten the central fixing bolt of the 07

camshaft.
Tip: 08
While installing the central fixing bolt of the camshaft,
the bolt can only be fastened by restricting the rotation 09
of the camshaft.
10
08-28 Assembly of Engine - Crankshaft Timing Pulley, Tensioner Pulley
Crankshaft Timing Pulley, Tensioner Pulley

Installation
01 1. Install Crankshaft Timing Pulley
(a). Sheathe catch for the crankshaft timing pulley.
02 Tip:
The two surfaces of the catch for the crankshaft timing
03 pulley are obviously different. One surface shall face
the crankcase, and the other surface shall face the
timing pulley. The directions shall be distinguished
04
while installing.
05
06
07
08
09 Tip:
The specific installing direction of the catch for the
10 crankshaft timing pulley is shown in the left picture,
and the bulged surface shall face outside (the side of
the timing pulley).
(b). Install the crankshaft timing pulley.

Tip:
The crankshaft timing pulley is generally easy to
install, and it is a little tight to remove for a new engine.
It shall not be installed forcibly if it is too tight, and it
shall be washed carefully to find out the causes.
Assembly of Engine - Crankshaft Timing Pulley, Tensioner Pulley 08-29
Tip:
One dot label on one side of the crankshaft timing
pulley is designed for confirm whether the crankshaft
timing pulley is correctly installed. This side shall face
outside but not face inside while installing. 01
02
03
04
05
06
2. Install Tensioner Pulley 07

(a). Put the tensioner pulley in the mounting position.
08
09
10
(b). Install the torsion spring bolts and adjusting

screws for the tensioner pulley.
Tip:
Install the torsion spring bolts and adjusting screws
without fastening them until the tensioner pulley
assembly can be easily moved manually.
Caution:
It is unnecessary to install the torsion spring at the
moment.
08-30 Assembly of Engine - Timing Belt, Front Cover
Timing Belt, Front Cover

Installation
01 1. Install Timing Belt
(a). Sheathe the timing belt in the mounting position.
02
03
04
05
06
07
08
09 (b). Adjust the timing belt to the correct position.

• Rotate the camshaft timing pulley to align the
10 dot label ② (locate on the radial line of label
①) on it with the bulged label ③ on the rear
cover of the timing belt.
• Rotate the camshaft to align the dot label ⑤
on the crankshaft timing pulley with the
bulged label ④ on the rear cover of the timing
belt.
• Adjust and install the timing belt under the
condition that the right part of the belt is
completely unloosened after the two timing
pulleys are angularly aligned with each other.
A: Camshaft Timing B: Tensioner Pulley
Gear D: Crankshaft Timing
C: Timing Belt Pulley
(c). Move the tensioner pulley assembly until the right

side of the belt is completely straightened. Check
the above labels to ensure they are in a line.
Assembly of Engine - Timing Belt, Front Cover 08-31
(d). Hang one end of the torsion spring on the

tensioner pulley support and hang the other end
on the screw of the water pump. Fasten the
adjusting screw for the belt tension.
Torque: 14.71~22.56N·m 01
Tip:
Apply GY-340 anaerobic adhesive on the bolt threads. 02
03
04
05
06
(e). Fasten the torsion spring bolts. 07

Torque: 14.71~22.56N·m
Tip: 08
Apply GY-340 anaerobic adhesive on the bolt threads.
09
10
(f). Press the belt between the camshaft and the

crankshaft with hands to confirm whether the
tension is within the specified range.
Strength: 29.4N
Reduction: 5.5~6.5mm
(g). Adjust the gap between valves after adjusting the belt tension to the specified range (Refer to
Chapter 9 Mechanical System -- Valve, Adjustment)
08-32 Assembly of Engine - Timing Belt, Front Cover
2. Install Front Cover

(a). Close the front cover.
Tip:
Replace new gaskets and spongy gaskets.
01
02
03
04
05
06
07 (b). Install and Fasten the fixing bolts for the front
cover.
08 Tip:
While installing fixing bolts for the front cover, it is
09 necessary to install the supporting sheets to be
installed together with the bolts. The bolts shall be
10 fastened one by one in the manner of diagonal
screwing.
Assembly of Engine - Crankshaft Pulley, Water Pump Pulley 08-33
Crankshaft Pulley, Water Pump Pulley

Installation
1. Install Crankshaft Pulley 01
(a). Put the flange assembly of the crankshaft pulley in
the mounting position. 02
03
04
05
06
07
08
(b). Install and fasten the bolt of the crankshaft pulley 09

under the condition of confirming the installation of
the flywheel locator. 10
Torque: 49.03~58.84N·m
2. Install Water Pump Pulley

(a). Put the water pump pulley in the mounting
position.
08-34 Assembly of Engine - Crankshaft Pulley, Water Pump Pulley
(b). Install and fasten the fixing bolts for the water
pump pulley.
Tip:
It will be more convenient to fasten the fixing bolts for
01 the water pump pulley until the water pump belt is
installed.
02
03
04
05
06
07
08
09
10
Assembly of Engine - Suspension Assembly, Dipstick 08-35
Suspension Assembly, Dipstick

Installation
1. Install Left Suspension Assembly 01
(a). Put the left suspension assembly in the mounting
position and align it with the mounting hole. 02
03
04
05
06
07
08
(b). Install and fasten the fixing bolts for the left 09
10
2. Install Right Suspension Assembly

(a). Put the right suspension assembly in the
mounting position and align it with the mounting
hole.
08-36 Assembly of Engine - Suspension Assembly, Dipstick
(b). Install and fasten the fixing bolts for the right
01
02
03
04
05
06
07 3. Install Engine Dipstick

(a). Install the guide pipe of the dipstick in position.
08
09
10
(b). Put the dipstick in its guide pipe.

Assembly of Engine - Inlet Hose, Intake Manifold 08-37
Inlet Hose, Intake Manifold

Installation
1. Install Inlet Hose Assembly 01
(a). Put the inlet hose assembly in the mounting
position. 02
Tip:
While installing, the inlet hose with strict requirements 03
for sealing shall be replaced with a new gasket and
applied with sealant.
04
05
06
07
08
(b). Install and fasten the fixing bolts for the inlet hose 09
assembly.
Tip: 10
The screw holes of the fixing bolts for the inlet hose
assembly are communicated with the inside of the
cylinder head, so the two bolts must be applied with
GY-340 anaerobic adhesive or equivalent before
installation.
2. Install Intake Manifold Assembly

(a). Put the intake manifold assembly in the mounting
position.
Tip:
Replace gasket for the intake manifold.
08-38 Assembly of Engine - Inlet Hose, Intake Manifold
(b). Install and fasten the fixing bolts and nuts for the
intake manifold.
Tip:
The nuts shall be fastened diagonally in alternation.
01
02
03
04
05
06
07 (c). Install and fasten the fixing bolt at the lower end of
the intake manifold.
08
09
10
(d). Install rubber water return pipe to the inlet hose.

Tip:
While installing the rubber water return pipe, sealant
shall be applied to the inner wall of its joint for
convenient installation and better sealing.
Assembly of Engine - Inlet Hose, Intake Manifold 08-39
(e). Install the rubber breather of the crankshaft to the

cylinder head cover.
01
02
03
04
05
06
07
08
09
10
08-40 Assembly of Engine - Thermostat, Fuel Rail Assembly
Thermostat, Fuel Rail Assembly

Installation
01 1. Install Thermostat Assembly
(a). Insert the thermostat into the mounting position.
02
03
04
05
06
07
08
09 (b). Close the thermostat cover.

Tip:
10 Replace a new gasket and apply sealant.
(c). Install and fasten the fixing bolts for the

thermostat cover.
Assembly of Engine - Thermostat, Fuel Rail Assembly 08-41
2. Install Fuel Rail Assembly

(a). Correctly insert the fuel rail assembly into the
mounting position.
Tip:
Make sure all the fuel injector assemblies are installed 01
in position one by one. While installing, force shall be
applied to the fuel injector assemblies one by one but 02
not to the fuel rails.
03
04
05
06
(b). Install and fasten two fixing bolts for the fuel rail 07
assembly.
08
09
10
(c). Install the vacuum connecting pipe.

08-42 Assembly of Engine - Generator
Generator
Installation
01 1. Install Support of Air Conditioning
Compressor
02 (a). Put the support of air conditioning compressor in
the mounting position and align it with the
03 mounting hole.
04
05
06
07
08
09 (b). Install and fasten three fixing bolts for the support
of air conditioning compressor.
10
2. Install Upper Support of Generator

(a). Put the upper support of generator in the
mounting position and screw the fixing bolts
manually.
Assembly of Engine - Generator 08-43
(b). Fasten two fixing bolts for the upper support of

generator.
01
02
03
04
05
06
3. Install Generator Assembly 07

(a). Carefully put the generator assembly in the
mounting position. 08
09
10
(b). Install the fixing bolt at the lower end of the

generator.
08-44 Assembly of Engine - Generator
(c). Push the generator assembly upwards and

sheathe the generator belt.
01
02
03
04
05
06
07 (d). Install the adjusting screw at the upper end of the

generator.
08 Tip:
Press down the generator to tension the generator belt
09 until reaching the suitable position. Fasten the
adjusting screw of the generator.
10
(e). Check whether the generator is suitably installed

or not.
• Press down the belt in the middle position
between the generator and the water pump
pulley to check whether the belt meets the
requirement or not.
Strength: 98N
Reduction: 10~15mm
Assembly of Engine - Oil Pressure Warning Unit, Oil Filter 08-45
Oil Pressure Warning Unit, Oil Filter

Installation
1. Install Oil Pressure Warning Unit 01
(a). Screw and fasten the oil pressure warning unit.
Torque: 11.77~4.71N·m 02
03
04
05
06
07
08
2. Install Oil Filter 09

(a). Screw and fasten the Oil Filter assembly.
Torque: 9.81~4.71N·m 10
08-46 Assembly of Engine - Exhaust Manifold
Exhaust Manifold
Installation
01 1. Install Exhaust Manifold Assembly
(a). Install the inner baffle assembly for exhaust
02 manifold.
03
04
05
06
07
08
09 (b). Put the exhaust manifold in the mounting position.
10
(c). Install and fasten fixing nuts for the exhaust

manifold.
Tip:
Fasten the nuts diagonally in alternation.
Assembly of Engine - Exhaust Manifold 08-47
(d). Install the lower heat shield pad of exhaust

manifold.
• Install and fasten the fixing nuts for heat shield
pad.
01
02
03
04
05
06
(e). Install the upper heat shield pad of exhaust 07

manifold.
08
09
10
(f). Install and fasten the fixing nuts for upper heat
shield pad of exhaust manifold.
08-48 Assembly of Engine - Ignition Coil Assembly

Installation
01 1. Install Support of Ignition Coil
(a). Put the ignition coil in the mounting position and
02 screw the fixing bolts for the support manually.
03
04
05
06
(b). Fasten the bolts with a speeder wrench.
07
08
09
10
2. Install Ignition Coil

(a). Put the ignition coil carefully in the mounting
position.
(b). Install and fasten two fixing bolts for the ignition
coil.
Assembly of Engine - Ignition Coil Assembly 08-49
3. Install Ignition Cables for Ignition Coil

(a). Insert the ignition coil terminals of the ignition
cables into the ignition coil.
01
02
03
04
05
06
(b). Insert the cylinder head terminals of the ignition 07

cables into the cylinder head.
08
09
10
(c). Press the ignition cables into corresponding soft

clips for ignition cables.
- Memo -
01
02
03
04
05
06
07
08
09
10
Mechanical System
Cylinder Head ..............................................................09-1
Parts Drawing ...........................................................09-1 01
Overhaul ...................................................................09-3
Rocker Arm Assembly................................................09-16 02
Parts Drawing .........................................................09-16
Overhaul .................................................................09-17 03
Valve ..........................................................................09-23
General...................................................................09-23
04
Adjustment..............................................................09-24
Overhaul .................................................................09-27
Camshaft....................................................................09-38 05
Parts Drawing .........................................................09-38
Overhaul .................................................................09-39 06
Piston and Connecting Rod Assembly .......................09-49
Parts Drawing .........................................................09-49 07
Overhaul .................................................................09-50
Crankshaft and Flywheel Assembly ...........................09-67 08
Parts Drawing .........................................................09-67
Overhaul .................................................................09-68
09
Crankcase ..................................................................09-81
Parts Drawing .........................................................09-81
Overhaul ....................................................................09-83 10
01
02
03
04
05
06
07
08
09
10
Mechanical System - Cylinder Head 09-1
Cylinder Head
Parts Drawing
01
02
03
04
05
06
07
08
09
10
09-2 Mechanical System - Cylinder Head
Washer Assembly of Bolt for Cylinder Head

1 Filler Cap 5
Cover
2 Cylinder Head Cover 6 Connecting Bolt for Cylinder Head
Rear End Cover and Gasket Assembly for
3 Cylinder Head 7
01 Cylinder Head
4 Bolt for Cylinder Head Cover
02
03
04
05
06
07
08
09
10
Overhaul
Caution:
While removing, the parts of the valve group must be concentrated together and marked with
identification codes so as to return them to their original positions in installation again. Before
01
removing the cylinder head from the engine and disassembling the valve mechanism, the
compression test shall be performed, and the results shall be recorded.
02
1. Perform Initial Inspection of Engine
(a). Before disassembling the engine, check the 03
crankcase and the cylinder head for the existence
of water leakage, oil leakage, etc. 04
05
06
07
08
09
10
Tip:
Check whether there is crack or damage in the fixed
position between the crankcase and the cylinder head.
(b). Clean the outside of the engine with steam or a

high-pressure water gun.
Caution:
When using the steam cleaner, wear goggles or
protective mask and protective clothing. Hot
steam may cause serious personal injuries.
(c). Operate the engine at low idle speed. Check

whether there is leakage of engine oil or coolant
between the cylinder head and the engine
cylinder.
01
02
03
04
05
06
07 (d). Listen whether there is chatter between the

cylinder head and the engine cylinder.
08 Tip:
While accelerating the engine, leakage can be
09 confirmed due to the chatter which generally
represents the leakage of the combustion chamber.
10 Immerse the overflow pipe in the coolant tank by filling
a transparent glass bottle with water half. Then
operate the engine at high idle speed until the
thermostat is switched on, and observe whether there
are steam bubbles in the water solution. It can be used
for identifying the leakage of combustion.
Caution:
Remove and check the cylinder head and all the
relevant parts if any leakage is found.
2. Remove Ignition Coil Assembly (Refer to Chapter 07 Disassembly of Engine -- Ignition Coil
Assembly, Removal)
3. Remove Exhaust Manifold Assembly (Refer to Chapter 07 Disassembly of Engine -- Exhaust
Manifold Assembly, Removal)
4. Remove Intake Manifold (Refer to Chapter 07 Disassembly of Engine -- Intake Manifold and
Inlet Hose, Removal)
5. Remove Cylinder Head Cover

(a). Unscrew the filler cap.
(b). Remove the fixing bolts for the cylinder head

cover with a speeder wrench.
01
02
03
04
05
06
(c). Remove the cylinder head cover. 07
08
09
10
6. Overhaul Cylinder Head Cover

(a). Check whether the filler cap has any crack or
corrosion. Replace it in case of damage.
(b). Wash the cylinder head cover with solvent, acidic

or alkaline substances.
Caution:
proposal from the manufacturer.
• Goggles and protective clothing shall be worn
to avoid personal injuries.
manufacturer.
(c). Clean the dirt retention on the cylinder head cover

with a hairbrush.
01
02
03
04
(d). Drying with compressed air.
05 Caution:
Suitable goggles and protective clothing shall be
06 worn while using compressed air.
Flying debris and dirt may cause personal injuries.
07
08
09
(e). Check whether the cylinder head has any crack or
10 corrosion. Replace it in case of damage.
(f). Check whether the gasket of the cylinder head

cover has any aging, corrosion or deformation.
Replace it in case of damage or deformation.
7. Remove Cylinder Head Assembly

(a). Remove the bolts for cylinder head.
01
02
03
04
05
06
Tip: 07
Remove the fixing bolts for the cylinder head
according to the order shown in the left picture. 08
Caution:
Remove the fixing bolts diagonally one by one. 09
Otherwise, there will be harmful influence on the
lower surface of the cylinder head. 10
(b). Clean the bolts with gasoline-base solvent.

Completely clear the deposits on the rod and
threads with a wire brush, soft wire wheel brush or
non-grinding shot blasting.
Caution:
manufacturer.
• Never clean cylinder head bolts with alkaline
or acid solutions. Otherwise, the parts will be
damaged.
(c). Visually check whether the bolts for the cylinder

head have any damaged thread and corroded
surface. Do replace them in case of damage or
corroded surface.
01
02
03
04
(d). Check whether the fixing bolts have any damaged
05 thread. Replace them in case of damage. Check
the two washers under the nuts simultaneously.
06 Replace them together in case of crack or
damage.
07
08
09
(e). Remove the cylinder head assembly.
10
8. Remove Rocker Arm Assembly (Refer to Chapter 07 Disassembly of Engine -- Cylinder Head,
Rocker Arm, Valve and Camshaft, Removal)
9. Remove Valve Assembly (Refer to Chapter 07 Disassembly of Engine -- Cylinder Head,
10. Remove Camshaft Assembly (Refer to Chapter 07 Disassembly of Engine -- Cylinder Head,
11. Clean Cylinder Head Primarily
(a). Clean the sealing surface between the cylinder
head and intake pipe.
Tip:
It is also necessary to clean the sealing surfaces
between cylinder head and the exhaust pipe.
Caution:
Never clear away carbon with sharp tools
randomly. Never abrade or scratch metal surfaces
while clearing carbon. Do the same for valves and
valve seats.
(b). Clean the cylinder and the combustion front on

cylinder head.
Caution:
Never clear away carbon with sharp tools
randomly. Never abrade or scratch metal surfaces 01
while clearing carbon. Do the same for valves and
valve seats. 02
03
04
12. Deeply Clean and Maintain Cylinder Head
(a). Clean the carbon deposits around the valves and
on the valves with a hairbrush. 05
06
07
08
09
(b). Blow out foreign matters with compressed air.
Caution:
10
worn while using compressed air.
Flying debris and dirt can result in personal injury.
(c). Clean excessive deposits in the container filled

with acidic solution, but must remove the
expansion plug firstly. Clean the deposits in the
coolant channel.
(d). Clear the combustion front of the cylinder head

with a manual grinding pad or equivalent cleaning
pad after cleaning.
Caution:
manufacturer.
(e). Clean valve seats and valve covers.

Caution:
• Goggles shall be worn while cleaning carbon
deposits so as to avoid injury.
01 • Valve seats in contact with wire wheels will be
damaged by the rotation of the wire wheels. In
this case, new valve seats must be cut or
02 installed with a new valve seat insert.
• Never use a poor-quality wire wheel which can
03 remain wires during operation to result in
additional pollution. Clean the carbon
deposits on the valve cover by using the
04 high-quality wire wheel installed on a bit or die
polisher.
05 (f). If the valve seat insert must be removed, clear the
deposits in the holes of the valve seat insert with a
06 wire brush and solvent.
07
08
09
10
(g). Clean the cylinder head with hot soap water
solution. Wash it with clean water.
(h). Dry with compressed air.

Caution:
worn while using compressed air.
13. Re-check Cylinder Head after Cleaning

(a). Inspect whether the cylinder head has any crack,
corrosion and discoloration having adverse
influence on use continuously.
Caution:
Pay close attention to the fuel injector hole,
combustion front and valve seat of the cylinder
head.
Tip:
Any cylinder head on which the crack does not extend
into the valve seat can be used continuously.
01
02
03
04
Tip:
Any cylinder head on which the crack extends into or 05
goes through the valve seat must be replaced.
Caution: 06
If the cylinder head is not replaced, the crack
extending into or going through the valve seat will
result in the disassembly of the valve seat insert or 07
lead to the damage of the engine.
08
09
Tip:
If it is still installed, check whether there is any crack or 10
ablated spot on the valve seat.
If the valve seat insert is damaged, it may be
necessary to replace the valve seat insert for some
cylinder heads.
(b). Check the thread holes on the rocker arm shaft

support and the cylinder head. Repair it by hole
expansion or replace it in case of damaged or
deformed threads.
(c). Measure the diagonal length of the lower surface

of the cylinder head so as to judge whether the
cylinder head is deformed.
Caution:
Different diagonal length indicates the deformation
of the cylinder head, and it shall be replaced. The
same diagonal length indicates normal cylinder
head.
(d). Check the flatness of the connecting surface of

the crankcase.
Tip:
Check the flatness of six positions by using a knife
01 straight edge and a thickness gauge. Polish the
positions higher than the following limit with a flat plat
02 and abrasive paper of about 400#. Any cylinder head
whose flatness still can not reach the specified limit
03 value must be replaced.
04
(e). Check the flatness of the joining surface of the
05 crankcase.
Caution:
06 The leakage of burning gas from the joining
surface of cylinder head is usually caused by the
uneven joining surface between the cylinder head
07 and the crankcase. Such leakage will reduce the
output power and increase the fuel consumption
08 per kilometer.
Limit of Flatness: 0.05mm
09
(f). Check the flatness of the joining surface of intake
10 and exhaust manifolds.
Tip:
Check the flatness of the manifold surface of cylinder
head by using a knife straight edge and a thickness
gauge to decide to polish the surface or replace the
cylinder head or not.
Limit of Flatness: 0.10mm
(g). Check the oil channel and water channel on the

cylinder head. Wash them with a water syringe.
Caution:
Generally, channels with big holes are water
channels, and those with small holes are oil
channel.
14. Install Camshaft (Refer to Chapter 08 Assembly of Engine -- Flywheel, Camshaft and Valve,
Installation)
15. Install Valves (Refer to Chapter 08 Assembly of Engine -- Flywheel, Camshaft and Valve,
Installation)
16. Install Rocker Arm Assembly (Refer to Chapter 08 Assembly of Engine -- Rocker Arm and
Cylinder Head, Installation)
17. Install Cylinder Head

(a). Rotate the crankshaft to make the four pistons in
the center of the cylinders.
Tip:
While installing flywheels, this step can be omitted if 01
the locator is used; if not, this step is very important.
Because the positions of the pistons and the valves 02
are not fixed while installing the cylinder head, some
valves will touch the top of pistons to result in the 03
damage of valves or pistons.
04
05
06
07
(b). Install the gasket for the cylinder head in position.
Tip:
Make sure that the gasket is correctly aligned with the 08
holes on the crankcase. If not, the crankcase may be
damaged. 09
10
(c). Put the cylinder head assembly on the crankcase

carefully and align it.
Tip:
The heavier component shall be lifted under the
assistance of others so as to avoid serious personal
injury.
(d). Put the fixing bolts for the cylinder head in and
screw them up
Torque: 53.94~58.84N·m
Tip:
01 Lubricate the threads of the mounting bolts and the
bottom of the tip of the bolts for the cylinder head with
02 clean engine oil.
03
04
05
06
07 Caution:
The bolts for the cylinder head shall be gradually
08 screwed up until reaching the specified value by
several times according to the order shown in the
09 left picture.
10
18. Install Cylinder Head cover

(a). Close the cylinder head cover.
Tip:
Any aged or corroded gasket for the cylinder head
cover shall be replaced.
(b). Install and fasten the fixing bolts for the cylinder
head cover.
Tip:
While installing the fixing bolts for the cylinder head,
never forget the clips and other components and parts 01
to be installed together with the bolts.
02
03
04
05
06
(c). Install the filler cap. 07
08
09
10
19. Install Intake Manifold Assembly (Refer to Chapter 08 Assembly of Engine -- Inlet Hose and
Intake Manifold, Installation)
20. Install Exhaust Manifold Assembly (Refer to Chapter 08 Assembly of Engine -- Exhaust
Manifold Assembly, Installation)
21. Install Ignition Coil Assembly (Refer to Chapter 08 Assembly of Engine -- Ignition Coil
Assembly, Installation)
09-16 Mechanical System - Rocker Arm Assembly
Rocker Arm Assembly

Parts Drawing
01
02
03
04
05
06
07
08
09
10
1 Rocker Arm Shaft 4 Rocker Arm

2 Sunk Screw for Rocker Arm Shaft 5 Adjusting Nut For Valve Rocker Arm
3 Rocker Arm Shaft Spring 6 Adjusting Screw for Rocker Arm
Mechanical System - Rocker Arm Assembly 09-17
Overhaul
Caution:
While overhauling, it is necessary to adjust, repair and replace parts if any over-wear or damage is
discovered.
01
1. Remove Cylinder Head Cover (Refer to Chapter 07 Disassembly of Engine -- Water Pump and
Cylinder Head Cover, Removal)
02
2. Remove Rocker Arm Component
(a). Fully loosen the 8 adjusting screws for the rocker 03
arm.
04
05
06
07
08
09
(b). Remove the 10 locking screws for the rocker arm 10

shaft.
(c). Pull out the rocker arm shaft. Remove the rocker arm
component and the rocker arm shaft spring.
3. Check Rocker Arm Assembly

(a). Clean all the parts with high-concentration cleaning
agent and hot water solution.
01
02
03
04
(b). Clear the deposits on the rocker arm support and
rocker arm assembly with a wire brush and a wire
05
wheel brush.
06
07
08
09 (c). Dry the parts rinsed in clean hot water with

compressed air.
10 Caution:
• Suitable goggles and a protective mask shall be
worn while using compressed air. Flying debris
and dirt can result in personal injury.
• The shaft seat made of metal powder still seems
wet even after cleaning and drying.
(d). Check whether there is any crack or deformed thread

of adjusting screws and fixing nuts for the valve
clearance. Replace them in case of damage.
(e). Check whether there is any deformed thread or worn

screw head of adjusting screws for the valve
clearance. Replace them in case of damage.
(f). Check whether there is any crack and over-wear in

the hole.
01
02
03
04
(g). Check the arc surface of the rocker arm.
Tip: 05
The rocker arm must be replaced if the arc surface is
seriously worn. 06
07
08
09
(h). Visually check each rocker arm shaft spring to
confirm whether there is any damage or deformation. 10
Replace the spring in case of any poor condition.
(i). Measure the inner diameter of rocker arm with a

vernier caliper or micrometer.
Item Standard Limit
Diameter of Rocker
--
Arm Hole
(j). Measure the outer diameter of rocker arm shaft with a

micrometer.
Item Standard Limit
Diameter of Rocker
01 --
arm shaft
Tip:
02 The rocker arm shaft shall be measured with the
micrometer, and the rocker arm shall be measured with the
03 caliper. The difference of the two readings is the clearance
between the rocker arm shaft and the rocker arm, and its
limit is specified. The rocker arm or rocker arm shaft or both
04
of them exceeding the limit shall be replaced.
Item Standard Limit
05
Clearance 0.005～
Intake 0.07mm
between 0.040mm
06 the Rock
Arm and 0.005～
Exhaust 0.01mm
07 the Rocker 0.040mm
08
(k). Check the linearity of the rocker arm shaft with
09 “V”-iron and a dial indicator. Repair or replace it by
using the cold deformation with a mallet in case of
exceeding the limit.
10
Limit of Linearity: 0.06mm
4. Install Rocker Arm Assembly

(a). Lubricate the rocker arm shaft with clean engine oil.
(b). Lubricate the inner hole of the rocker arm with clean
engine oil.
(c). Assemble rocker arm.

Caution:
• All the rocker arm components must be installed
in the original positions and directions.
• The adjusting screws shall be installed until they 01
stop, and the locking nuts shall be installed.
02
03
04
(d). Install the rocker arm shaft on the cylinder head by
passing through the rocker arm hole. 05
Caution:
While installing rocker arm shaft, fully unscrew but 06
never remove the valve adjusting screws.
07
08
09
10
Tip:
It is unnecessary to distinguish the same two rocker arm
Exhaust side
shafts, but each rocker arm shaft can only adopt one
assembling position. The specific installing position is
shown in the left picture.
Front end Rear end
Intake side
Caution:
The positions of the rocker arm and the rocker arm
spring installed on the rocker arm must be correct
as the installing positions shown in the left picture.
Front end Rear end

(e). Install the locking screws for the rocker arm shaft.
Tip:
All the locking screws shall be screwed up one by one
from the middle to both sides.
01
02
03
04
05
06
07
5. Adjust Valve Clearance (Refer to Chapter 9 Mechanical System -- Valve, Adjustment).
08
6. Install Cylinder Head Cover (Refer to Chapter 08 Assembly of Engine -- Cylinder Head Cover
and Water Pump, Installation)
09
10
Mechanical System - Valve 09-23
Valve
General
1. Valve train has certain direct influence on the normal operation of engine. Valve train shall ensure
that the mixed gas can duly get into the cylinder at the maximum inflating amount for the intake 01
travel, and the exhaust gas in the cylinder can be duly exhausted from the cylinder to reduce the
residual exhausted gas as much as possible for the exhaust travel. Meanwhile, the valve is required 02
to be closed tightly for the travels of compression and work.
2. Some components of the valve train are subject to the impact or impact load of high-temperature 03
gas, and some others are not well lubricated. As a result, such components will be worn, corroded
or deformed during the long-term use, the technical performances and fitting relations will be
04
destroyed and finally lead to faults and failures of the components.
05
06
07
08
09
10
09-24 Mechanical System - Valve
Adjustment
01
2. Rotate the crankshaft until the marked line on
02 vibration damper pulley of crankshaft is aligned with
the timing pointer. At the moment, the piston of
03 Cylinder 1 or that of Cylinder 4 shall be in the dead
center of the compression travel.
04 Caution:
The engine shall be in a cold state.
05
06
07
3. Judge whether the piston of Cylinder 2 or that of
08 Cylinder 3 is in the dead center of the
compression travel.
Tip:
09
Shake the rocker arms of the intake valve and exhaust
valve of Cylinder 2 or Cylinder 3 manually. If there is a
10 clearance between the valve rocker arms while shaking
Cylinder 2, it is indicated that its piston is in the dead
center of the compression travel. The valve rocker arm of
Cylinder 3 shall be shaken if that of Cylinder 2 can not be
shaken. If there is a clearance between the valve rocker
arms, it is indicated that its piston is in the dead center of
the compression travel.
4. Adjust Clearance of Valves

(a). Check the clearance of valves with a feeler gauge
when Cylinder 2 is in the dead center of the
compression travel.
Fixed value for clearance of valves (cold state):
0.13~0.18mm
Tip:
Value for clearance of intake valves and exhaust valves
shall be the same.
(b). Adjust by using a screwdriver matched with a wretch.

(c). When the clearance of valves is too small, rotate the

adjusting screw for clearance of valves
counterclockwise until the feeler gauge can be
inserted into it with a little of resistance.
Caution: 01
While rotating the adjusting screw for clearance of
valves to adjust the clearance of valves, it is 02
preferable to adjust by using a screwdriver matched
with a wretch. 03
04
(d). When the clearance of valves is too small, rotate the
adjusting screw for clearance of valves clockwise 05
until the feeler gauge can be inserted into it with a
little of resistance. 06
07
08
09
(e). Adjust the clearances according to the order of
clearances of Valves 1, 2, 4 and 5 as shown in the left 10
picture.
(f). Rotate the crankshaft for 360° and then align the
marked line on vibration damper pulley of crankshaft
with the timing pointer to adjust the clearances of the
rest of valves.
(g). When Cylinder 3 is in the top dead center of

compression travel, check the clearance for valves
with a feeler gauge.
Fixed value for clearance of valves (cold state):
0.13~0.18mm
Tip:
Value for clearance of intake valves and exhaust valves
shall be the same.
(h). When the clearance of valves is too small, rotate the

adjusting screw for clearance of valves
counterclockwise until the feeler gauge can be
inserted into it with a little of resistance.
01
02
03
04
(i). When the clearance of valves is too small, rotate the
05 adjusting screw for clearance of valves clockwise
until the feeler gauge can be inserted into it with a
06 little of resistance.
07
08
09
(j). Adjust the clearances according to the order of
10 clearances of Valves 3, 6, 7 and 8 as shown in the left
picture.
Overhaul
01
3. Remove Cylinder Head Assembly (Refer to Chapter 07 Disassembly of Engine -- Cylinder 02
Head, Rocker Arm, Valve and Camshaft, Removal)
03
4. Remove Valve
(a). Remove tapered cotter of valve. 04
Tip:
Compress the valve spring with a valve spring 05
compressor to expose and remove the tapered cotter of
valve.
06
07
08
(b). Remove valve spring base, valve spring and valve
spring retainer. 09
10
(c). Pry the valve oil seal with a screwdriver.

Caution:
Valve oil seal is a quick-wear part. Any pried valve oil
seal must be replaced.
01
02
03
04
05
06
07 (d). Take out the valve from one side of the combustion
chamber.
08
09
10
5. Overhaul Valve Components

(a). Measure the verticality of valve spring with a steel
square.
Caution:
Replace the valve spring if the measured value
exceeds the specified limit value.
Verticality of valve spring: 2.0mm
(b). Compress the spring to the installation height with a

spring tester. Measure the tension of the compressed
spring.
Caution:
Replace the valve spring if the measured tension
exceeds the specified limit value.
Item Standard Limit
Preload of Valve 254.8~294N for 235.2N at
Spring 40mm 40mm
(c). Measure the free height of valve spring with a vernier

caliper.
Caution:
Replace the valve spring if the measured value
exceeds the specified limit value. 01
Item Standard Limit
Free Length of
47.7mm 46.5mm 02
Valve Spring
03
04
(d). Visually check the over-wear of valve stem tip or
scratch of valve stem surface. Replace the valve in 05
case of serious wear.
06
07
08
09
Tip:
Polish the valve stem by using a grinding pad and solvent 10
in case of not so serious wear.
(e). Over-wear of cylinder head and valve stem. Replace

them in case of serious wear.
(f). Check whether there is any wear on the end surface

of each valve stem.
Tip:
The end surface of valve stem will sink or deform
irregularly due to its intermittent fit with rocker arm during
operation. Polish the end surface of valve stem by using
an oilstone if necessary. Replace the valve if its grinding
amount reaches 0.1mm (calculated from that before
grinding).
Service limit for the end surface of valve stem: 0.5mm
(g). Measure the diameter of valve stem with a

micrometer.
The range of diameter for replacing valve stem is as
follows:
01 Item Standard Limit
Diameter Intake --
02 of Valve
Stem Exhaust --
03
04
(h). Measure the deflection of valve with a dial indicator.
05 Decide whether it is necessary to replace it according
to the following limit value.
06 Deflection at Intake 0.12mm
the End of
Exhaust 0.16mm
07 Valve Stem
08
09
10 (i). Measure the thickness at the big end of valve.

Replace it in case of exceeding the limit of thickness.
Thickness at the big end of valve:
Standard Limit
Intake 0.6mm
0.8mm~1.2mm
Exhaust 0.7mm
(j). Measure the angle of contact conical surface of valve

seat. Replace the valve, valve guide pipe and valve
seat together if the measured value exceeds the limit.
Standard: 45°
(k). Measure the radial skip of the 45° conical surface of

each valve by using a dial indicator and “V”-iron so as
to ensure the sealing between valve and valve seat.
Limit for radial skip of 45° conical surface: 0.03mm
(l). Polish valve seat in two steps. Firstly, apply cruder

polishing paste on valve surface; secondly apply finer
polishing paste. Polish by using the common
polishing method every time.
Caution: 01
Remove the polishing paste on the surfaces of valve
and valve seat after polishing. Perform contact check
02
by using red lead to confirm the contact is in the
width of valve seat and there is no notch on its
contact color bar. Make sure to perform the 03
inspection. If necessary, adjust the clearance of
valves after installing cylinder head and valve 04
components.
(m). Apply red lead evenly and fully on the 45° conical 05
surface of valve. Put the conical surface into the
valve cap to make it contact with valve seat.
Tip: 06
At the moment, the imprint of the contact surface of valve
seat must be a continuous color bar. The width of the 07
color bar must be within the following range:
Standard Width Intake 08
for Color Bar of 1.3~1.5mm
Exhaust
Valve Seat 09
10
(n). Make sure that the valve seat unable to be in even
contact with valve or the valve seat whose contact
width is not within the specified range must be
repaired by the method of grinding or cutting, grinding
and polishing in order..
Tip:
Perform cutting with a taper reamer for 15°, 75° and 45° in
order. The cutting must result in ideal bar width.
Tip:
The cutting sequence shall be the same as that for
exhaust valve seat, but the cutting angles shall be
different.
6. Remove Valve Guide Pipe

(a). Knock down and withdraw the valve guide pipe with a
simple tool so as to remove it from the top of cylinder
head.
(b). Enlarge the hole of the withdrawn guide pipe with a

Φ12mm reamer so as to remove burrs. The diameter
of the enlarged hole shall be within the following
range:
01 Diameter of Intake
Φ12.030~
Valve Guide
Exhaust Φ12.048mm
02 Pipe Hole
03
04
7. Overhaul Valve Guide Pipe
05 (a). Measure the inner diameter of valve guide pipe with a
caliper.
Internal
Intake -
Diameter
07
Valve
Exhaust -
Guide Pipe
08 Tip:
The valve stem shall be measured with the micrometer,
09 and the valve guide pipe shall be measured with the
caliper. The difference of the two readings is the fit
10 clearance between the valve and the valve guide pipe,
and its limit is specified. The valve or the valve guide pipe
or both of them exceeding the limit shall be replaced.
Item Standard Limit
Fit
Intake 0.020~0.050mm 0.07mm
Clearance
of Valve
Exhaust 0.030~0.060mm 0.09mm
Guide Pipe
8. Install Valve Guide Pipe

(a). Lubricate all the holes and outer wall of valve guide
pipe with engine oil.
Caution:
The valve guide pipe will be worn quite early if the
valve guides and valve stems are not lubricated.
(b). Knock the valve guide pipe in with a special tool from
the other side of the combustion chamber.
Tip:
Apply engine oil on the outside surface of valve guide pipe
while installing. Install a new valve guide pipe and check 01
its height.
Reference height: 16.5mm 02
Caution:
The length of guide pipe shall be different for intake 03
valve and exhaust valve. It is 52.5mm for intake valve
and 54.5mm for exhaust valve.
04
9. Remove Valve Seat
(a). Check whether the valve seat is worn. Remove and 05
replace it in case of wear.
Methods for removal valve seat: 06
Perform arc welding for the inside of valve seat. Cool the
valve seat. Pry out the valve seat with a screw driver. 07
Caution:
Never damage the cylinder head while removal.
08
09
10. Install Valve Seat 10

(a). Install valve seat.
Tip:
While installing, press accessories with a bench press and
force the valve seat to be in position.
Caution:
The pressure applied by the bench press shall not be
overlarge, otherwise the valve seat will be damaged.
(b). Clear carbon deposits on the surface of valve seat.

Process with a valve reamer to minimize the scratch
and the rough area so as to recover its contact width
to the standard value.
Caution:
Only the scratched and rough parts can be cut off.
Never cut too much.
11. Grind Valve Seat

(a). Apply a little of oil or Prussian blue on the surface of
valve seat.
Tip:
Use a new or repaired valve. Check whether the fit with
the valve seat is perfect.
(b). Install the valve applied with oil or Prussian blue.
01
02
03
04
(c). Rotate it for a quarter circle leftwards and rightwards
05 for several times.
06
07
08
09
(d). Take out the valve.
10
(e). Examine the contact surface with the valve seat. Oil
or Prussian blue must fully and evenly covers on the
surface to form a complete annular band.
(f). If the contact annular band can not meet the

requirement and locates on the conical surface of
valve, trim the valve seat with 30° and 45° reamers.
(g). If the contact annular band can not meet the

requirement and locates under the conical surface of
valve, trim the valve seat with 60° and 45° reamers.
01
02
03
04
(h). Apply grinding paste on the surface of valve seat.
05
06
07
08
09
(i). Grind the valve until the perfect fit between the valve
and the valve seat is obtained. 10
(j). Completely clean the valve, valve seat and valve
guide pipe after grinding.
12. Install Valve

(a). Install the valve oil seal on the valve guide pipe with a
special tool.
(b). Lubricate all the holes of valve guide pipe and valve
stem with clean engine oil.
Tip:
The valve guide pipe will be worn quite early if the valve
01 guides and valve stems are not lubricated.
Caution:
02 Distinguish the intake valve from the exhaust valve
according to the differences in the diameter at the big
03 end and the shape at the disk end. The disk end
surface of the intake valve is in the shape of a
concave circular arc, and that of the exhaust valve is
04 flat.
05 (c). Put the valve stem in the mounting position.

Tip:
06 If the valve to be installed is the same as the removed
one, make sure that the valve is installed in the same
07 position as the removed one. Replace new valve oil seal
at the same time.
08
09
10
(d). Install valve spring base, valve spring and valve

spring washer.
Tip:
Each valve spring has a big-interval end and a
small-interval end. The small-interval end shall be
arranged at the bottom while installing the spring.
Caution:
The removed valve oil seal must be replaced.
(e). Install valve tapered cotter.

Tip:
Compress the valve spring with a valve spring
compressor to expose the mounting position of tapered
cotter. Put in the valve tapered cotter and release the 01
valve spring. Beat the valve spring retainer with a valve
plastic hammer as soon as the valve assembly is locked 02
by the tapered cotter. Make sure that the valve lock is
correctly installed by knocking with the plastic hammer. 03
Caution:
Goggles shall be worn to reduce the possibility of
personal injury. If the lock clamp is not correctly 04
installed, it will burst out while knocking the valve
spring retainer with the plastic hammer. 05
06
13. Install Rocker Arm Assembly (Refer to Chapter 08 Assembly of Engine -- Rocker Arm and 07
Cylinder head, Installation)
14. Install Cylinder Head Assembly (Refer to Chapter 08 Assembly of Engine -- Rocker Arm and 08
15. Adjust Clearance of Valves (Refer to Chapter 9 Mechanical System -- Valve, Adjustment). 09
and Water Pump, Installation) 10
09-38 Mechanical System - Camshaft
Camshaft
Part Drawing
01
02
03
04
05
06
07
08
09
10
1 Front Oil Seal Assembly, Camshaft 3 Camshaft Thrust Plate

2 Camshaft 4 Cross Recessed Countersunk Head Screw
Mechanical System - Camshaft 09-39
Overhaul
01
3. Remove Cylinder Head (Refer to Chapter 07 Disassembly of Engine -- Cylinder Head, Rocker
Arm, Valve and Camshaft, Removal) 02
4. Remove Water Pump Pulley and Crankshaft Pulley (Refer to Chapter 07 Disassembly of
Engine -- Water Pump Pulley and Crankshaft Pulley, Removal) 03
5. Remove Front Cover and Timing Belt (Refer to Chapter 07 Disassembly of Engine -- Front
Cover and Timing Belt, Removal) 04
6. Remove Tensioner Pulley and Crankshaft Timing Pulley (Refer to Chapter 07 Disassembly of
Engine -- Tensioner Pulley and Crankshaft Timing Pulley, Removal) 05
7. Remove Camshaft Timing Gear
(a). Remove central bolt of camshaft 06
Tip:
If this bolt is not unscrewed before loosen the belt, the 07
camshaft timing gear will rotate along with it while
removing, and the bolt shall be removed by being fixed 08
with a tool.
09
10
(b). Remove camshaft timing gear.

8. Remove Rear Cover

(a). Remove the fixing bolts for the rear cover.
01
02
03
04
05
06
07 (b). Remove the rear cover.
08
09
10
9. Remove Camshaft Component

(a). Remove the fixing bolts for the rear end cover of
cylinder head.
(b). Remove the rear end cover of cylinder head.
01
02
03
04
05
06
(c). Remove the cross recessed countersunk head 07

screws for the camshaft thrust plate with a cross
screwdriver. Remove the camshaft thrust plate. 08
09
10
(d). Pull out the camshaft to the rear end.

10. Overhaul Camshaft

(a). Clean parts with solvent.
Caution:
The cleaning by solvents and acid or alkaline
01 substances shall be subject to the usage proposal
from the manufacturer. Goggles and protective
02 clothing shall be worn to avoid personal injuries.
03
04
(b). Clear the deposits on the camshaft with a wire brush
05 and a soft wire wheel brush.
06
07
08
09
(c). Dry it with compressed air.
10 Caution:
Suitable goggles and a protective mask shall be worn
while using compressed air.
(d). Check whether the inner bole of the camshaft is

plugged or whether engine oil or grease accumulates
on the inner side of the camshaft.
(e). Check the linearity of the camshaft with a dial

indicator. Replace it if the linearity exceeds the limit.
Limit for Linearity of
0.10mm
Camshaft
(f). Measure the height (H) of each cam. If the reading of

the micrometer is smaller than the limit, the camshaft
must be replaced.
Cam Height (H) Standard Limit
Intake Cam 36.152mm 36.100mm 01
Exhaust Cam 36.152mm 36.100mm
Eccentric Cam of 02
30.300mm 33.000mm
Gasoline Pump
03
04
(g). Measure the diameter of each journal in two positions 05

and two directions to get four readings.
06
07
08
09
10
(h). Check the diameter of the cylinder head camshaft

hole with a tramegger.
Tip:
Four readings shall be measured for each hole, and the
clearance between the camshaft hole and the journal shall
be calculated according to these data. The camshaft shall
be replaced if any clearance exceeds the limit. Replace
the cylinder head as well if necessary.
Item Standard Limit

Radial
0.050～0.09mm 0.15mm
Clearance
Tip:
Measure the journal in six positions.
Diameter of Camshaft Diameter of Cylinder
Journal Head Camshaft Hole
Aφ44.234～φ44.250mm φ44.300～φ44.325mm
Bφ44.234～φ44.250mm φ44.234～φ44.250mm
Cφ44.034～φ44.050mm φ44.100～φ44.125mm
Dφ44.834～φ44.850mm φ43.900～φ43.925mm
Eφ44.634～φ44.650mm φ43.700～φ43.725mm
Fφ44.434～φ44.450mm φ43.500～φ43.525mm
(i). Visually check whether there is any pitting or crack on

the camshaft surface. If yes, the camshaft must be
replaced.
01
02
03
04
11. Overhaul Camshaft Gear
05 (a). Clean camshaft gear with solvent.
Caution:
06 The cleaning by solvents and acid or alkaline
substances shall be subject to the usage proposal
07 clothing shall be worn to avoid personal injuries.
08
09
(b). Clear the deposits on the camshaft gear with a wire
10 brush and a soft wire wheel brush.

Caution:
(d). Check whether there is any crack and corrosion on

the bolt holes of the camshaft and camshaft gear.
(e). Check whether there is any corrosion on the

camshaft gear teeth. Check whether there is any
crack or broken gear teeth on the camshaft gear.
Replace the gear in case of damage.
01
02
03
04
(f). Clear any corrosion, burrs or bulged metal by using a
grinding pad. Replace the gear if the corrosion, burrs 05
or bulged metal can not be cleared by using the
grinding pad. 06
07
08
09
12. Overhaul Camshaft Thrust Plate
(a). Measure the thickness of cam thrust plate with a 10
screw micrometer. It must be replaced if the
thickness exceeds the specified limit.
(b). Visually check the camshaft thrust plate. It must be

replaced in case of any damage or crack.
13. Install Camshaft

(a). Drop clean engine oil or equivalent lubricating oil on
the journal of the camshaft.
01
02
03
04
05
06
07 (b). Place the camshaft.

Tip:
08 Insert the front end of the camshaft into the rear end of the
cylinder head towards its front end.
09
10
(c). Install the camshaft thrust plate.

Tip:
Install the camshaft in a suitable position. Install the
camshaft thrust plate with one hand, and rotate the
camshaft with the other hand simultaneously to confirm
that the camshaft can rotate smoothly.
(d). Install and fasten the fixing bolts for the camshaft
thrust plate.
01
02
03
04
05
06
(e). Close the rear end cover of the cylinder head. 07

Tip:
Replace a new gasket.
08
09
10
(f). Install and fasten the fixing bolts for the rear end
cover of the cylinder head.
14. Install Rear Cover and Camshaft Timing Gear (Refer to Chapter 08 Assembly of Engine --
Rear Cover and Camshaft Timing Gear, Installation)
15. Install Crankshaft Timing Pulley and Tensioner Pulley (Refer to Chapter 08 Assembly of
Engine -- Crankshaft Timing Pulley and Tensioner Pulley, Installation)
16. Install Timing Belt and Front Cover (Refer to Chapter 08 Assembly of Engine -- Timing Belt
and Front Cover, Installation)
17. Install Crankshaft Pulley and Water Pump Pulley (Refer to Chapter 08 Assembly of Engine --
Crankshaft Pulley and Water Pump Pulley, Installation)
18. Install Cylinder Head (Refer to Chapter 08 Assembly of Engine -- Rocker Arm and Cylinder
Head, Installation)
01 20. Install Cylinder Head Cover (Refer to Chapter 08 Assembly of Engine -- Cylinder Head Cover
02
03
04
05
06
07
08
09
10
Mechanical System - Piston and Connecting Rod Assembly 09-49
Piston and Connecting Rod Assembly

Part Drawing
01
02
03
04
05
06
07
08
09
10
1 Top Compression Ring 7 Connecting Rod Bushing

2 Third Compression Ring 8 Connecting Rod Body
3 Oil Ring Component 9 Bearing Shell, Connecting Rod
4 Piston 10 Connecting Rod cap
5 Piston Pin 11 Connecting Rod Bolt
6 Retainer Ring, Piston Pin 12 Connecting Rod Nut
09-50 Mechanical System - Piston and Connecting Rod Assembly
Overhaul
01
02 3. Remove Cylinder Head (Refer to Chapter 07 Disassembly of Engine -- Cylinder Head, Rocker
Arm, Valve and Camshaft, Removal)
03 4. Remove Water Pump Pulley, Crankshaft Pulley (Refer to Chapter 07 Disassembly of Engine
-- Water Pump Pulley and Crankshaft Pulley, Removal)
04 5. Remove Front Cover and Timing Belt (Refer to Chapter 07 Disassembly of Engine -- Front
Cover and Timing Belt, Removal)
05 6. Remove Tensioner Pulley and Crankshaft Timing Pulley (Refer to Chapter 07 Disassembly of
Engine -- Tensioner Pulley and Crankshaft Timing Pulley, Removal)
7. Remove Camshaft Timing Gear and Rear Cover (Refer to Chapter 07 Disassembly of Engine
06 -- Camshaft Timing Gear and Rear Cover, Removal)
8. Remove Flywheel and Oil Pan (Refer to Chapter 07 Disassembly of Engine – Flywheel and Oil
07 Pan, Removal)
9. Remove Oil Filter and Oil Pump (Refer to Chapter 07 Disassembly of Engine -- Oil Filter and
08 Oil Pump, Removal)
09 10. Remove Crankshaft Rear End Cover

(a). Remove the six fixing bolts for crankshaft rear end
cover.
10
(b). Remove the crankshaft rear end cover.


(a). Rotate the crankshaft to make the piston assembly to
be removed reach the bottom dead center, which
means expose the piston connecting rod vertically for
convenience of removal. 01
02
03
04
05
06
(b). Remove the nuts of piston connecting rod. 07
08
09
10
(c). Remove the bearing shell of connecting rod. Mark

each bearing shell of connecting rod on its movable
lug.
(d). Clear the carbon deposit in the piston cylinder.

Caution:
01 proposal from the manufacturer.
• Goggles and protective clothing shall be worn to
02 avoid personal injuries.
• Some solvents are inflammable and toxic. Before
03 use, carefully read the manual of the
manufacturer.
04
05
06
07 (e). Push out the piston assembly.

Tip:
08 Push out the piston assembly by using wood or rubber
substance but never using metal substance to avoid
09 damaging the end surface of connecting rod.
10
(f). Take out the piston assembly from the other side.
(g). Assemble a set of parts of piston assembly and mark

them with cylinder No.
Tip:
If these parts will be used continuously, the piston and
connecting rod assembly must be installed in the same 01
cylinder gasket as that used while removing. Make sure
that is corrected matched with the grinded joining surface. 02
03
04
05
06
(h). Rotate the crankshaft to expose the connecting rod 07

nuts of other two cylinders. Remove the remaining
piston assembly according to the above methods. 08
Tip:
If the piston assembly will not be used immediately, the 09
connecting rod and the piston assembly shall be stored in
a container to avoid damage.
10

(a). Remove five piston rings by using a special piston
ring remover.
(b). Pry out two inspect rings on both sides of piston with
a sharp-nose screwdriver.
(c). Rush out the piston pin with a punch pin.
01
02
03
04
13. Overhaul Bearing
05 Inspect whether the bearing is damaged.
Tip:
Replace the bearing having any of the following damages.
06
• Corrosion in pit
• Peeling
07 • Corrosion
• Damage of bolt
08 • Scratch
09
14. Overhaul Connecting Rod
10 (a). While connecting the assembled connecting rod with
the connecting rod journal, measure the thrust
clearance at the big end of each connecting rod. If the
measured clearance exceeds the specified limit, any
connecting rod or Crankshaft exceeding the limit shall
be replaced.
Item Standard Limit
Thrust Clearance at
0.10~0.20 mm 0.30mm
Big End
1 Width at Big End 21.95～22.00mm

2 Width of
Connecting Rod 22.10～22.13mm
Journal
(b). Correct connecting rod.

Tip:
Put the connecting rod on a plate to inspect whether there is
any bending or torsion. Replace it in case of exceeding the
limit.
Bending Limit 0.05mm
Torsion Limit 0.10mm
(c). Remove the bush with a suitable rod and hammer.

Caution:
A hammer can also be used while installing. The bush
shall be aligned with the oil hole of the connecting
rod. The hole of the newly installed bush shall be 01
polished with a pinhole polisher.
02
03
04
(d). Clean the connecting rod with solvent.
Caution: 05
The cleaning by solvents and acid or alkaline
substances shall be subject to the usage proposal 06
clothing shall be worn to avoid personal injuries.
07
08
09
(e). Clean the contact surface between the connecting
rod and the connecting rod cap with a nylon 10
hairbrush.
Caution:
The contact surface between the connecting rod and
the connecting rod cap is not a machined one, so it
must be processed carefully to avoid damaging the
parts.
(f). Dry the connecting rod with compressed air.

Caution:
The pressure of compressed air used for cleaning
shall be no more than 207 kPa. Protective clothing,
goggles/mask and gloves shall be worn.
(g). Inspect whether the connecting rod has any cinch

mark, crack, burrs, scratch or wear.
Caution:
If any part of the connecting rod or connecting rod
cap has obvious wear, both of them shall be replaced
as an assembly. The contact surface between the
connecting rod and the connecting rod cap is not a
machined one. Unless there is deep cinch mark or
crack on the surface, otherwise it shall not be
considered that the surface is damaged.
(h). Inspect whether there is any cinch mark, crack, burrs,

scratch or wear on the connecting rod cap.
01
02
03
04
(i). Inspect whether the pinhole of the connecting rod
05 piston is damaged.
Caution:
06 The small-end hole of the connecting rod does not
have any engine oil channel aligned with the hole on
the bush. The hole on the bush is only used in
07 manufacture.
08
09
(j). Measure the clearance between the small-end hole
10 and the piston pin. The connecting rod shall be
replaced if the clearance exceeds the limit.
Item Standard Limit
Clearance
Between 0.003~0.016
0.05mm
Small-End Hole mm
and Piston Pin
1 Clearance of
Φ16.003～Φ16.011mm
Small-End Holes
2 Diameter of Piston
Φ15.995～Φ16.000mm
Pin
(k). Clearance between connecting rod journal and the

bearing shell of connecting rod: Measure the
clearance with a thin fuse.
Tip:
Cut off a segment of thin fuse whose length is almost
equal to the width of the bearing shell. Put the thin fuse on
the connecting rod journal axially in avoidance with the oil
hole.
Tip:
Screw up the bolts for bearing shell, connecting rod body
and connecting rod cap.
Caution:
Never rotate the crankshaft or connecting rod while 01
the thin fuse is on the clearance. Distinguish the front
end and the rear end while installing the connecting 02
rod cap on the connecting rod journal.
Tightening torque for the connecting rod cap: 03
27.46~31.38N/m
04
(l). Remove connecting rod cap.
05
06
07
08
09
(m). Measure the thickness of depressed thin fuse. The
measurement must be taken at the widest part. 10
Item Standard Limit
Clearance
Between Bearing
shell Of 0.020~0.040
0.080mm
Connecting Rod mm
and Connecting
Rod Journal
Tip:
In case of exceeding the above limit, grind the connecting
rod journal into a small grade, and match it with a small
grade of bearing shells of connecting rod. Both shall refer
to the table below.
Size of Bearing shell of Diameter of Crankshaft

Connecting Rod Connecting Rod Journal
Standard 37.985~38.000mm
Reduced by 0.25mm 37.735~37.750mm
Reduced by 0.50mm 37.485~37.500mm
Caution:
There will be some allowance for the clearance
specification provided connecting rod shell of a lower
grade is used. Radial clearance of connecting rod
shell of a lower grade: 0.020～0.070mm.
15. Overhaul Piston Pin

(a). Visually inspect whether there is any crack, scratch or
other damage on the piston pin. Repair it if
necessary.
01
02
03
04
(b). Measure the outer diameter of piston pin with a
05 micrometer in three different positions and two
different directions.
06 Standard size of piston pin: Φ28h4 (0-0.006).
07
08
09
16. Overhaul Piston
10 (a). Soak the piston overnight to loosen the carbon
deposits. Immerse the piston in cold cleaning solution
for parts.
Caution:
• Never clean piston by using the shot blasting
method. The shot blasting material embedded in
aluminum will result in the damage of piston.
• Never clean piston in any container filled with
acidic solution, otherwise the piston will be
damaged.
(b). Clean piston with the mixture of high-concentration

cleaning agent and hot water.
Caution:
Never use steel brush which can damage the ring
groove.
(c). Dry the piston with compressed air.

Caution:
(d). Inspect whether there is any damage and wear on

the piston skirt, pinhole, the top and piston ring
groove.
01
02
03
04
(e). The horizontal height at the bottom end of the piston
skirt is 30mm. 05
Standard
Φ65.465~Φ61.495mm 06
Diameter of Piston
Enlarged
Φ65.965~Φ62.995mm
07
08
09
(f). While measuring the clearance of opening, put the
piston ring in the cylinder, push it to the bottom of the 10
cylinder hole. The ring must be replaced if the
measured clearance exceeds the limit.
Item Standard Limit
Top and Second
Opening 0.15~0.35
Compression 0.7mm
Clearance mm
Rings
of Piston
Combined Oil 0.30~0.90
Ring 1.8mm
Ring mm
(g). Measure the clearance between the piston ring

groove and the piston by using a feeler gauge. If the
clearance between the piston ring groove and the
piston exceeds the specified limit value, the piston
01 ring shall be replaced. If the clearance still does not
meet the requirement after the new piston ring is
02 installed, the piston must be replaced.
Caution:
03 The piston rings must be replaced in group.
Clearance between the piston ring and the piston ring
groove:
First Ring
05 0.03~0.07mm 0.12mm
Ring groove
Clearance Second
06 in Slot Ring 0.02~0.06mm 0.10mm
groove
07 Thickness
First Ring groove 1.47~1.49mm
Second Ring
of Piston 1.47~1.49mm
08 groove
Ring
Scraper Ring 0.45mm
09 Width of First Ring groove 1.52~1.54mm
Ring Second Ring
1.51~1.53mm
groove groove
10
(h). Polish the carbon deposits on the piston top and

piston ring plug by using a soft metal friction tool.
17. Inspect Piston Ring

(a). Inspect the wear of grains of the piston ring.
Tip:
The black grinding paint on the right side of piston ring
reduces rapidly and is invisible sometimes, which
indicates that the grains of the piston ring are worn. It is
generally considered as that the ring surface is completely
worn. The rapid reduce of paint will generally keep the
sharp edge at the bottom of the middle ring. The
longitudinal scratches concentrated on the top ring also
indicate the occurrence of worn grains. Worn grains can
be resulted from the following causes:
• Absorption of grinding materials
• Incomplete cleaning in previous maintenance.

• Particles embedded in the cylinder hole.
• Higher smoke content in engine oil due to the
prolonged interval of engine oil discharge.
• Scratches and cinch marks. 01
Caution:
While installing piston ring, the inner bevel of the 02
piston ring shall be installed in alignment with the top
of piston. The piston ring shall be installed according 03
to the mark if available.
18. Install Piston Assembly 04

(a). Install the connecting rod bolts on the connecting rod.
05
06
07
08
09
10
(b). Install upper shell of bearing shells of piston

connecting rod.
Tip:
Before assembly, the cylinder and all the parts must keep
clean. The connecting rods and bearing shells shall be
cleaned with a piece of clean cloth without fluffing.
Caution:
Make sure that the back sides of connecting rod and
connecting rod bearing are clean without any debris.
Never lubricate the back side of any connecting rod
bearing.
Caution:
Make sure that the locating lug of the bearing shell is
aligned with the locating groove on the connecting
rod cap while installing.
01
02
03
04
05
06
07 (c). Drop clean engine oil or equivalent lubricating oil on

the inner side of the bearing shell.
08
09
10
(d). Lubricate the piston ring and the piston skirt with
clean engine oil.
(e). Rotate the piston rings and adjust the position of their
openings as shown in the picture.
Tip:
The opening of each piston ring shall not be aligned with
the opening of the piston pin or other piston rings. The 01
piston rings can not be correctly sealed due to the
incorrect positions of their openings. 02
Caution:
While installing piston ring, the inner bevel of the 03
piston ring shall be installed in alignment with the top
of piston. The piston ring shall be installed according
to the mark if available. 04
(f). Compress the piston ring into the working position 05

with a piston ring compressor.
Tip: 06
An annular cylinder can be self-made with an iron sheet in
case of no special tool. 07
08
09
10
(g). Rotate the crankshaft to make the journal of the
connecting rod to be installed in the position of the
bottom dead center.
(h). Apply a thin layer of clean engine oil on each cylinder

wall.
(i). Insert the connecting rod into each cylinder hole until
the piston ring compressor touches the top of the
cylinder..
01
02
03
04
05
06
07 Tip:
The arrow on top of the piston shall be aligned to point at
08 the front of the engine. The long end of the connecting rod
and the notch on the piston skirt shall be on the exhaust
09 side of the. If not, it shall be inspected whether the piston
is correctly installed on the connecting rod.
10 Caution:
The engine will be seriously damaged if it is not
operated in accordance with this step.
(j). Jack the cylinder with the piston ring compressor.

Pass the piston through the piston ring compressor
and push it into the cylinder hole.
Caution:
If the piston can not move freely, it shall be removed
to inspect whether the piston ring is broken or
damaged.
(k). Install the lower shell of the bearing shell of the

connecting rod on the bearing shell cover of the
connecting rod.
Caution:
• Make sure that the back sides of the connecting 01
rod and the connecting rod bearing are clean
without any debris. Never lubricate the back side 02
of any connecting rod bearing.
• If a new bearing is not used, the old one must be 03
installed in the same connecting rod cap which is
used while installing.
04
Caution:
Make sure that the locating lug of the bearing shell is 05
aligned with the locating groove on the connecting
rod cap while installing. 06
07
08
09
(l). Lubricate the inner side of the lower shell of the 10

bearing shell of the connecting rod with clean engine
oil.
(m). Install the connecting rod cap on the corresponding

journal of the crankshaft.
Caution:
The arrow on the upper end surface of the connecting
rod cap must point at the rear end (installing end of
flywheels).
01
02
03
04
05
06
07 (n). Install the connecting rod nuts and screw them up

with a torque wrench in alternation by several times
08 according to the angular tightening method.
Torque: 27.46~31.38N·m
09 Tip:
The connecting rod nuts shall be gradually screwed up in
pairs and in alternation.
10 (o). Measure the backlash between the connecting rod
body and the crankshaft.
Tip:
The backlash between the connecting rod and the
crankshaft shall be measured but not that between the
connecting rod cap and the crankshaft.
Tip:
If the piston, crankshaft, connecting rod or cylinder is changed/replaced, it is necessary to measure the
extrusion of the piston from the cylinder combustion front. The steps are as follows:
• Install a dial indicator on the cylinder head, and zero it.
• Move the dial indicator over the piston top to eliminate all sidewise movements.
• Rotate the crankshaft clockwise and counterclockwise, observe the maximum reading of the dial
indicator, and record the measurement result. Judge the result.
19. Install Crankshaft Rear End Cover (Refer to Chapter 08 Assembly of Engine -- Crankshaft
Rear End Cover and Oil Pump, Installation)
20. Install Oil Filter and Oil Pan (Refer to Chapter 08 Assembly of Engine -- Oil Filer and Oil Pan,
Installation)
21. Install Flywheel (Refer to Chapter 08 Assembly of Engine -- Flywheel, Camshaft and Valve,
Installation)
Head, Installation)
Mechanical System - Crankshaft and Flywheel Assembly 09-67
Crankshaft and Flywheel Assembly

Part Drawing
01
02
03
04
05
06
07
08
09
10
1 Crankshaft 4 Driving Pulley Flange

2 Camshaft Front Oil Seal Assembly 5 Driving Pulley
3 Crankshaft Timing Pulley
09-68 Mechanical System - Crankshaft and Flywheel Assembly
Overhaul
1. Remove Flywheel
(a). Remove the six fixing bolts for the rear end cover of
01
the cylinder head.
Tip:
02 While removing flywheels, it will be easier to fix the
flywheel by installing a flywheel locator.
03
04
05
06
07
08 (b). Remove the flywheel locator.
09
10
(c). Remove flywheel assembly.

2. Overhaul Flywheel
(a). Visually inspect the working surface of the flywheel,
and repair or replace it in case of wear, grooving or
worn gear ring. Visually inspect the teeth of the
flywheel, and repair or replace it in case of wear or 01
damage.
02
03
04
(b). Measure burn on the flywheel surface with a dial
indicator to confirm that the burn shall be within the
05
range limit.
Burn on the surface: 0.2mm
06
07
08
09
Cylinder Head Cover, Removal) 10
5. Remove Cylinder head (Refer to Chapter 07 Disassembly of Engine -- Cylinder Head, Rocker
Arm, Valve and Camshaft, Removal)
6. Remove Water Pump Pulley and Crankshaft Pulley (Refer to Chapter 07 Disassembly of
Engine -- Water Pump Pulley and Crankshaft Pulley, Removal)
7. Remove Front Cover and Timing Belt (Refer to Chapter 07 Disassembly of Engine -- Front
9. Remove Camshaft Timing Gear and Rear Cover (Refer to Chapter 07 Disassembly of Engine
-- Camshaft Timing Gear and Rear Cover, Removal)
10. Remove Oil Pan (Refer to Chapter 07 Disassembly of Engine – Flywheel and Oil Pan,
Removal)
11. Remove Oil Filter and Oil Pump (Refer to Chapter 07 Disassembly of Engine -- Oil Filter and
Oil Pump, Removal)
12. Remove Crankshaft Rear End Cover and Disconnect Connecting Rod from Crankshaft (Refer
to Chapter 07 Disassembly of Engine -- Crankshaft Rear End Cover and Piston Assembly,
Removal)
13. Remove Crankshaft Assembly

(a). Unscrew the bolts for the main bearing cover one by
one.
Tip:
The bolts shall be unscrewed one by one in a cross
manner. But never remove them.
Caution:
The removal operation shall be in accordance with the
removal order shown in the left picture.
01
02
03
04
05
06
07 (b). Remove the main bearing covers. Arrange them in

order.
08 Tip:
• The main bearing cover shall be shaken by seizing
09 the bolts with both hands or vibrated to loose by using
a rubber hammer, and then taken out.
10 • Each main bearing cover shall have a label for
assistance of memory.
(c). Remove the main bearing shell.

Tip:
Never forget to remove the thrust washers of the
crankshaft. Remember to record the mounting positions
and the front and back faces to avoid mistake in
installation.
(d). Each main bearing shell shall be marked on its

movable lug according to the cylinder No.
01
02
03
04
(e). Take out the crankshaft assembly.
Tip: 05
The heavier component or assembly shall be lifted under
the assistance of others or by using suitable hoisting 06
equipment so as to avoid serious personal injury.
07
08
09
10
(f). Take out the upper shells of the main bearing shell.
Tip:
The upper shells shall be taken out one by one and
marked with the cylinder No. on the movable lugs. Never
forget to remove the thrust washers of the crankshaft.
Remember to record the mounting positions and the front
and back faces to avoid mistake in installation.
14. Overhaul Main Bearing shell and Main Bearing

Cover
(a). Clean main bearing cover and other parts with steam
or hot soap water.
Caution:
When using the steam cleaner, wear goggles or
protective mask and protective clothing. Hot steam
may cause serious personal injuries.
(b). Dry the parts with compressed air.

Caution:
01 Flying debris and dirt can result in personal injury.
02
03
04
(c). Inspect whether there is any deep scratch or
05 overheating indication on all the main bearing covers
and main bearing bolts.
06 Caution:
The cylinder must be replaced if the main bearing
cover is damaged.
07
08
09
(d). Inspect whether there is any deep scratch or
10 overheating indication on the main bearing shell.
Caution:
The complete set must be replaced if the main
bearing shell is damaged.
(e). Inspect whether there is any cinch mark or burrs on

the joining surface of the bearing shell seat.
Tip:
The cinch mark or burrs can be grinded by using a
grinding pad. If the cinch mark or burrs can not be
removed by the grinding pad or equivalent, the bearing
must be replaced.
15. Overhaul Crankshaft

(a). Clean crankshaft and gear with hot soap water.
(b). Clean the engine oil hole with a hard non-metal

hairbrush.
01
02
03
04
(c). Dry it with compressed air. Make sure the
compressed air can blow out of the screwed hole and 05
engine oil channel at each end of the crankshaft.
Caution: 06
Flying debris and dirt can result in personal injury. 07
08
09
(d). Inspect whether the threads at both ends of the
crankshaft have any damage. Replace the crankshaft 10
in case of damage.
Caution:
Never finish the threads on the crankshaft, otherwise
the engine will be seriously damaged.
(e). Visually inspect the middle of crank arm and the ends
of both the crank arm and the connecting rod journal.
Replace them in case of any crack.
(f). Inspect whether there is any scratch. Repair it in case

of slight scratch, and replace it necessarily in case of
serious scratch.
(g). Measure the difference of main journal or connecting

rod journal with uneven wear in the diameter direction
with a dial indicator. Any main journal or connecting
rod journal worn seriously or unevenly and exceeds
01 the limit, the crankshaft shall be repaired or replaced.
Limit of uneven wear: 0.010mm
02 Caution:
The main journal or connecting rod journal shall be
re-grinded, and the diameter shall be fine-finished to
03
the required size.
04
(h). Put the crankshaft on a V-block carefully, rotate it
05 slowly, and measure the circular run-out. If the
circular run-out of the crankshaft exceeds the
specified limit, the crankshaft must be replaced.
06
Circular run-out limit of crankshaft main journal:
0.06mm
07 Caution:
Measure the runout at the central journal.
08
09
16. Measure Thrust Clearance of Crankshaft
10 Install the crankshaft, main bearing shell, crankshaft
thrust washer and main bearing cover in the
crankcase, and screw up the main bearing bolts.
Measure the axial movement of crankshaft.
Thickened thrust washer must be used in case of
exceeding the specified limit.
Tightening torque for main bearing cover bolts of
crankshaft: 42.17~47.7N·m.
Item Standard Limit
Clearance of
Crankshaft 0.13~0.28mm 0.35mm
Thrust Washer
Standard 2.500mm
Thickness of Thickened Type:
2.563mm
Crankshaft 0.125mm
Thrust Washer Thickened Type:
2.625mm
0.250mm
17. Clearance Between Main Journal and Main

Bearing Shell
(a). Measure the clearance with a thin fuse.
Tip:
Cut off a segment of thin fuse whose length is almost
equal to the width of the bearing shell. Put the thin fuse on
the main journal axially. Screw up the bolt.
(b). Remove bolt and take out the thin fuse.
01
02
03
04
(c). Measure the thickness of depressed thin fuse. The
measurement must be taken at the widest part. 05
Caution:
Each of five main bearing covers shall have an arrow. 06
The arrow of each bearing must point at the front end
and correspond to the main journal (according to the
number of cylinder holes). 07
Item Standard Limit 08

Clearance
between Main 09
0.020~0.040mm 0.080mm
Journal and Main
Bearing shell 10
If the clearance between the main journal and main
bearing shell exceeds the limit, the main journal shall be
grinded into the next small grade and matched with the
main bearing shell of corresponding grade.
Diameter of Main Bearing

Diameter of Main Journal
shell
Standard Φ49.985～Φ0.000mm
Reduced by 0.25mm Φ49.735～Φ49.75mm
Reduced by 0.25mm Φ49.485～Φ49.50mm
Clearance Between
Reduced Main Bearing 0.020～0.070mm
shell and Main Journal
18. Install Crankshaft

(a). Install the upper shells of main bearing shell in the
corresponding positions.
Tip:
01 Install the upper shells of main bearing shell in the
corresponding positions carefully in order. Make sure that
02 the back of the bearing shell is clean without any debris.
Each upper shell of main bearing shell shall be in the
03 center of shall groove. Apply a suitable amount of engine
oil or equivalent on the inner side of the arched surface of
the bearing shell after installation.
04
05
06
07 Caution:
Make sure that the locating lugs of the bearing shells
08 are aligned with the locating grooves on the cylinder
saddle of the main bearing shells while Installation.
09
10
(b). Install crankshaft thrust washer.

Caution:
While installing the thrust washer, its oil groove shall
face outwards.
(c). Drop clean engine oil or equivalent lubricating oil on

the inner side of the main bearing shell.
Caution:
Never drop engine oil on the outer side of main
bearing shell. 01
02
03
04
05
06
(d). Install the crankshaft assembly in the corresponding 07

position.
Caution: 08
• The heavier component or assembly shall be
lifted under the assistance of others or by using 09
suitable hoisting equipment so as to avoid
serious personal injury. 10
• The crankshaft shall be installed carefully to
avoid damaging the crankshaft main bearing,
especially thrust washer and main bearing
journal. The service life of engine will be
shortened due to the damage of crankshaft.
(e). Drop clean engine oil or equivalent lubricating oil on

the main journal of installed crankshaft.
(f). Apply engine oil on the lower shell of the main

bearing shell, and install the lower shell on the main
bearing cover.
Tip:
01 Slide the lower shell of main bearing shell into the main
bearing shell cover from one side, and flatten its end
02 surface.
03
04
Caution:
05 Make sure that the locating lug of the bearing shell is
aligned with the locating groove on the main bearing
06 cover while Installation.
07
08
09
(g). Install the main bearing covers in order
10 Tip:
• While installing the rear main bearing cover, pay
attention to the shedding of crankshaft thrust washer.
• Install the main bearing covers in the original
positions according to labels without mistakes.
Tip:
There are numbers for identification on each crankshaft
main bearing cover, and the crankshaft main bearing
covers shall be installed in order without confusion.
Caution:
While arranging the crankshaft main bearing covers
on the main bearing seat of crankcase, the arrow on
each cover shall point at the front end (direction of
pulley).
(h). Put the main bearing cover bolts into the mounting
holes in order and screwed them up slightly and
manually.
Tip:
Drop a suitable amount of engine oil on the threads of 01
main bearing cover bolts.
02
03
04
05
06
(i). Screw up the main bearing bolts according to certain 07

sequence and torque.
Torque: 42.17~47.07N·m 08
09
10
Tip:
• The bolts shall not be tightened by one time but shall
be screwed up a little every time to the specified
torque gradually.
• The main bearing bolts must be screwed up
according to a certain sequence (as shown in the left
picture).
Tip:
The installed crankshaft shall be rotated for several circles to inspect whether it rotates smoothly and
flexibly.
19. Inspect Timing Belt and Timing Pulley

(a). Inspect whether there is any wear, crack and other
abnormality on the timing belt. Replace it if
necessary.
01
02
03
04
(b). Inspect whether there is any wear, crack and other
05 abnormality on the timing pulley. Replace it if
necessary.
06
07
08
09
20. Install Piston Assembly (Refer to Chapter 08 Assembly of Engine -- Piston Assembly,
10 Installation)
21. Install Crankshaft Rear End Cover (Refer to Chapter 08 Assembly of Engine -- Crankshaft
Rear End Cover and Oil Pump, Installation)
22. Install Oil Filter and Oil Pan (Refer to Chapter 08 Assembly of Engine -- Oil Filter and Oil Pan,
Installation)
23. Install Flywheel (Refer to Chapter 08 Assembly of Engine -- Flywheel, Camshaft and Valve,
Installation)
Head, Installation)
Mechanical System - Crankcase 09-81
Crankcase
Part Drawing
01
02
03
04
05
06
07
08
09
10
09-82 Mechanical System - Crankcase
1 Oil filter Assembly 5 Spacer Plate

2 Connecting Pipe 6 Lock Pipe Support
3 Oil Pump Assembly 7 Long Dipstick Assembly
01 4 Baffle Assembly 8 Crankcase Assembly
02
03
04
05
06
07
08
09
10
Overhaul
1. Remove Crankcase (Chapter 07 Disassembly of Engine)
01
2. Remove Cylinder Gasket
Tip:
Install a cylinder gasket remover on the cylinder gasket, 02
inspect whether the bottom edge of the cylinder gasket is
firmly supported by the base on the remover shaft, and 03
then slowly rotate the hand wheel of removal shaft
counterclockwise to pull out the cylinder gasket. 04
05
06
3. Overhaul Crankcase
(a). Clean the crankcase in a cleaning tank. 07
Caution:
• The cleaning by solvents and acid or alkaline 08
• Goggles and protective clothing shall be worn to 09
avoid personal injuries.
• Clean by the solution which can not damage the 10
camshaft bushing.
• The cleaning by the cleaning tank shall be subject
to the operation instructions from the
manufacturer.
• The cleaning by solvents shall be subject to the
operation instructions from the manufacturer.
(b). Completely clean the cylinder with steam and then

dry it with compressed air.
Caution:
• When using the steam cleaner, wear goggles or
protective mask and protective clothing.
• Hot steam may cause serious personal injuries.
Caution:
In order to reduce the possibility of engine damage,
make sure all the debris shall be cleared from the
screwed holes and engine oil channels. If the cylinder
will not be used at once, one layer of protective oil
shall be applied so as to prevent rusting. The cylinder
shall be covered to prevent dirt from adhering to
engine oil.
09-84 Mechanical System - Crankcase
(c). After cleaning the cylinder, reinspect whether there is

any crack, abrasion and color change influencing the
usage on the cylinder.
01
02
03
04
(d). Measure the lengths of four edges and the diagonal
05 line on the crankcase. If the measured values exceed
the specified limit, the crankcase must be replaced.
06
07
08
09
(e). Measure the flatness of the crankcase surface with a
10 ruler and a feeler gauge. Repair or replace the
crankcase in case of exceeding the specified limit.
(f). Measure the diameter of each cylinder hole with a

tramegger at 15mm, 45mm and 90mm to the top
longitudinally and horizontally and obtain a total of six
data accordingly. Determine whether the maximum
diameter difference between any two cylinder holes
exceeds the limit or not. If the difference exceeds the
limit listed in the following table or the wall of any
cylinder hole has serious cinch marks or erosion
(wear), all the cylinder holes shall be bored to the
next larger size, and enlarged pistons shall be used
while installing the engine.
0.25mm
Enlarged Piston
0.50mm
Caution:
If any one of the four cylinder holes needs enlarging,
the four cylinder holes shall be bored to the enlarged
size simultaneously and keep the same size.
While replacing piston or assembling enlarged piston, the
clearance between the piston and the auxiliary cylinder of
cylinder hole shall be within the following range:
• Limit of diameter difference between any two cylinder
• Clearance between piston and auxiliary cylinder of

cylinder hole: 0.040~0.050mm.
(g). Visually inspect whether there is any crack or
corrosion on the cylinder gasket. If yes, the cylinder
gasket must be replaced. 01
02
03
04
(h). Clean the oil channels and water channels on the
crankcase with a water gun after removing all the 05
accessories of the crankcase.
06
07
08
09
4. Install Cylinder Gaskets
• Install the cylinder gaskets with a special tool. 10
Tip:
The surfaces of the cylinder gaskets and cylinder holes
shall be completely cleaned with new kerosene or diesel.
The surfaces of the cylinder gaskets and cylinder holes
shall be dried with compressed air. All the foreign matters
must be cleared carefully from the cylinder gaskets and
cylinder holes before installing the cylinder gaskets.
5. Assemble Crankcase (Refer to Chapter 08 Assembly of Engine)

Electronic Fuel Injection System
Electronic Fuel Injection System ..................................10-1
Genera .....................................................................10-1 01
System Functions .....................................................10-1
Components of Electronic Fuel Injection System .........10-3 02
Engine Control Module .............................................10-3
Crankshaft Position Sensor ......................................10-4 03
Ignition Coil Assembly ..............................................10-5
Ignition Cable ..........................................................10-7
04
Coolant Temperature Sensor ...................................10-8
MAP/MAT Sensor...................................................10-10
Fuel Rail Assembly.................................................10-11 05
Valve EGR..............................................................10-13
Throttle Body Assembly..........................................10-14 06
Oxygen Sensor.......................................................10-16
07
08
09
10
11
12
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Electronic Fuel Injection System - Electronic Fuel Injection System 10-1
Electronic Fuel Injection System

General
Electronic fuel injection system includes the main elements of sensors, electronic control module (ECM),
fuel injector, etc. It takes the electronic control module (ECM) as the center and accurately measure the 01
rotating speed of engine and various relevant input signals through the MAT/MAP sensors, the throttle
position sensor and the coolant temperature sensor which are installed on the intake system and the 02
crankshaft position sensor which is assembled on the transmission housing. Meanwhile, the system
accurately calculates the actual air intake of engine according to the input signal of coolant temperature 03
during the operation of engine, and then calculates the required quantity of fuel injection according to the
air intake. Fuel shall be pumped from the fuel tank by an electric fuel pump and pressurized, filtered by
04
the fuel filter, sent to the fuel guide rail above the engine, sent into the fuel rail distribution device, and
then injected by the fuel injector regularly. The system also adopts a closed-loop fuel control system.
The electronic control module (ECM) can determine the air-fuel ratio during the operation of engine 05
according to the changes of oxygen content in the exhaust measured by the oxygen sensor installed on
the exhaust pipe, and can correct and compensate the real-time fuel supply conditions of engine 06
according to the feedback to the induction signal so as to ensure that engine can operate in the state of
ideal air-fuel ratio and ensure that the three-way catalytic converter equipped for the system can play the 07
best roles in effectively reduce the contents of carbon monoxide (CO), hydrocarbon (HC) and nitride
(NOx). 08
System Functions 09
Idling Closed-Loop Control
Closed-loop control refers to the idling operating mode control of gasoline engine under normal working 10
temperature. The electronic fuel injection system fully closes the throttle in the idling operating mode and
controls the air intake during the idling operation of gasoline engine by using the idle speed regulator
11
arranged on the throttle body assembly. Meanwhile, the ECM of gasoline engine monitors the real-time
value of rotating speed of gasoline engine, compares it with the idle speed target value preset by the
system, and duly regulates the idle speed control valve and angle of advance for ignition according to 12
the fluctuation of rotating speed of gasoline engine so as to ensure the stable operation of gasoline
engine. 13
Ignition Timing Control System 14

The electronic fuel injection systems for this product series of gasoline engines are all direct ignition
control systems which have the functions of ECM automatic ignition timing control and charging time
setting control. By using the advanced technology of direct ignition without a distributor, the system
outputs ignition signals to the primary winding with double ignition coils, provides ignition signal current
for the coils of grouped Cylinders 1, 4 and grouped Cylinders 2, 3 respectively to ignite the two spark
plugs connected with the ignition coils of grouped Cylinders 1, 4 and grouped Cylinders 2, 3
simultaneously through the built-in ignition drive circuit inside the engine electronic control module.
During normal usage, other components of the ignition system need not any maintenance except
replacing the spark plugs duly. During the operation of gasoline engine, the electronic controller can
determine the set value of angle of advance for ignition according to the load information and rotating
speed signals and obtains the accurate angle of advance for ignition according to the information of
coolant temperature, etc. to determine the ignition timing.
Multipoint Fuel Injection System

This product series of gasoline engines all adopt sequential multipoint fuel injection system. The four fuel
injectors of the four cylinders injects according to the sequence of 1-3-4-2. Each fuel injector ejects once
when the gasoline engine crankshaft rotates for every two circles.
Waste Gas Exhaust System

The gasoline engine control system is a closed-loop fuel control system with a heating oxygen sensor.
The oxygen sensor provides the signal of oxygen concentration in the exhaust to the ECM which then
regulates the quantity of fuel injection according to the signal, so that the gasoline engine can operate in
the state of idea air-fuel ration (14.7:1) to ensure the optimal conversion efficiency of the catalytic
converter.
10-2 Electronic Fuel Injection System - Electronic Fuel Injection System
Steam Exhaust Pollution Control

The gasoline engine control system controls the cleaning speed and cleaning occasion for the charcoal
canister according to the operating conditions of the gasoline engine to control the canister cleaning of
vehicles.
01 Fault Diagnosis
The gasoline engine control system has the function of fault self-diagnosis. When the components of the
system have any fault, ECM will start the fault indicator lamp to remind the driver of maintenance. At the
02 moment, the system can ensure the customer to drive the vehicle to the maintenance station for
maintenance under the condition of protecting the gasoline engine.
03
04
05
06
07
08
09
10
11
12
13
14
Electronic Fuel Injection System - Components of Electronic Fuel Injection System 10-3
Components of Electronic Fuel Injection System

Engine Control Module
1. Appearance 01
02
03
04
05
06
2. Mounting Position
Engine control module (ECM) is installed in the cab.
07
08
09
10
11
3. Component Instructions
Engine control module (ECM) as the core component of the electronic fuel injection system controls 12
the gasoline engine through sensors and actuator. In operation, the sensors transmit various
parameters of operating conditions to ECM, such as intake pressure, coolant temperature, intake 13
temperature, oxygen concentration in waste gas, etc., and ECM will give an instruction to the
actuator after corresponding treatment to regulate the gasoline engine through the actuator. 14
4. Composition and Principle
The ECM electronic control unit of gasoline engine is a microprocessor taking a single-chip
microcomputer as the core, and it is composed of a hardware circuit board and control software. It
processes the signals from various sensors, judges the operating conditions of gasoline engine and
sends control signals of optimal fuel injection, ignition, etc. to the actuator, so that the gasoline
engine can be in the optimal operating condition all the time.
5. Working Parameters
Normal working voltage: 9V ~ 16V
Abnormal working voltage: 6.3V ~ 9.0V, 16V ~ 24V
Working temperature: -40℃ ~ 85℃
Overvoltage protection: -12V ~ 24V
6. Fault Diagnosis
ECM electronic control unit has a lower fault rate. If the ECM electronic control unit has any problem,
the lines, sensors and other peripheral components shall be troubleshot firstly, and ECM shall be
replaced after confirming that all the peripheral components do not have any fault.
7. Cautions for Removal and Installation

The installation of ECM electronic control unit requires dustproof and waterproof conditions and
good heat radiation, and its metal housing must be isolated with the vehicle body.
10-4 Electronic Fuel Injection System - Components of Electronic Fuel Injection System
Crankshaft Position Sensor

1. Appearance
01
02
03
04
05
06 It shall be installed in the connecting position
between transmission and engine.
07
08
09
10
11 3. Component Instructions
The crankshaft position sensor installed on the transmission housing provides the signals of rotating
speed and crankshaft phase, and the crankshaft phase provides a reference point for fuel injecting
12 timing and ignition timing. When Cylinders 1 and 4 of gasoline engine are in the top dead center, the
crankshaft position sensor just faces to the falling edge of the 20th tooth of flywheel signal gear teeth
13 (counting clockwise from the notch between two gear teeth of flywheel; observing from the rear end
of gasoline engine).
14
Crankshaft is composed of a permanent magnet and a coil. When the crankshaft is rotating, the
gear teeth and groove on the gear ring pass through the sensor at different distances to make the
sensor induce the changes of reluctance, and the sensor can produce variable output signals
accordingly. The waveform of the output signals reflects the rotating positions of the crankshaft, and
the frequency of the output signals is in direct ratio with the rotating frequency of crankshaft.
The shielding layer wrapped outside the crankshaft position sensor is connected with the grounding
wire so as to prevent electromagnetic interference.
Working temperature:-40℃~165℃
Air clearance: 0.25mm ~ 1.75mm
Output: 400mV@60rpm
Coil resistance: 540Ω
Coil inductance: 240mH@1kHz
Note: Air clearance refers to the clearance between the magnetic core end of sensor and top of
signal gear teeth.

1. Appearance
01
02
03
04
05
It shall be installed at the rear end of cylinder head. 06
07
08
09
10
3. Component Instructions 11
By using the advanced technology of direct ignition without a distributor, the gasoline engine
management system outputs ignition signals to the primary winding with double ignition coils
through the built-in ignition drive circuit inside the electronic controller. The ignition coil contains two 12
independent coils which control the spark plugs of Cylinders 1, 4 and Cylinders 2, 3 respectively.
When the two spark plugs of Cylinders 1, 4 (or Cylinders 2, 3) are ignited simultaneously under the 13
control of electronic controller, the gas pressure inside the cylinder which is in the top dead center of
exhaust is quite low, so the electrodes of the spark plug can be broken down to ignite by only a little 14
ignition energy (about 5% of the total ignition energy), and the ignition actually belongs to invalid
ignition. However, the mixed gas inside the other cylinder which is in the top dead center of
compression travel has very high density, so the spark plugs of the cylinder can be ignited only by
higher ignition energy (about 95% of the total ignition energy), and the ignition of this cylinder
belongs to valid ignition.

The ignition coil is consisted of a primary winding, a secondary winding, an iron core, etc. The
primary winding is charged when the battery voltage is applied to the primary winding. The charging
will be interrupted once ECU cuts off the return circuit of the primary winding, and high voltage can
be induced in the secondary winding at the same time.
Primary resistance: 0.5Ω ± 0.05Ω
Secondary resistance: 5200Ω ± 400Ω
Working temperature: -40℃~125℃
Primary inductance: 2.75mH ± 0.25mH
Secondary inductance: 17.5H ± 1.2H
Service voltage range: 6V ~ 16V
Secondary output voltage: 34KV
Shortest ignition duration: 0.8ms
6. Fault Diagnosis
Ignition coil produces a large amount of heat during operation under normal conditions, but the
over-high temperature of ignition coil will increase its resistance and result in engine faults, such as
unstable operation, automatic flameout, etc.
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Ignition Cable
1. Appearance
01
02
03
04
05
It shall be installed on the side of cylinder head cover. 06
07
08
09
10
Because electronic fuel injection system adopts high-energy ignition and high-tension ignition,
selected ignition cable must be able to withstand enough voltage and inhibit the radio interference
waves emitted by the ignition system during high-energy ignition. Ignition cable is used for 12
transmitting the secondary voltage produced by the ignition coil to the spark plugs of the cylinders in
order, so that electric spark can be produced among the electrodes of the spark plugs to ignite the 13
mixed gas and operate the gasoline engine.
14
5. Fault Diagnosis
(a). Inspection of spark plugs
Clean the spark plugs with a wire brush. Visually inspect whether the electrodes of the spark plugs
are burnt and whether the threads and insulators are damaged. Replace the spark plug in case of
any damage.
Generally, the spark plugs shall be replaced once after 10000km of running.
(b). Inspection of Ignition Cable
Never pull or bend the ignition cable, otherwise the conductor inside the ignition cable will be
damaged.
Ignition cable is of an anti-interference type, so the resistance at both ends of each cables shall be
no more than 25kΩ, otherwise the ignition cable must be replaced.
(c). Observation of Spark-over in Different Cylinders
Remove the spark plugs of the two cylinders for ignition of the same group, connect the spark plugs
with corresponding ignition cables, reliably ground the threads of the spark plug and the cylinder
bodies, start the gasoline engine, and observe the spark-over of the spark plugs.
While inspecting the spark-over, the fuel injection plug must be unplugged, otherwise the
discharged unburned gasoline will burn at the three-way catalytic converter and will burn it out in a
short time; the two spark plugs of the same group must be removed at the same time, otherwise the
ignition system can be damaged.

The ignition cable shall be plugged in by holding the ignition cable sheath with hands, and shall be
pulled out slightly by holding the sheath but not pulled out forcibly by holding the conducting wire so
as to avoid the damage of ignition cable.
Coolant Temperature Sensor

1. Appearance
01
02
03
04
05
06 It shall be installed at the middle part of intake
manifold.
07
08
09
10
The coolant temperature sensor installed on the circulating water channel on the intake manifold
provides coolant temperature signal for correcting the quantity of fuel injection and ignition timing.
12
13 The coolant temperature sensor (CTS) is composted of a thermistor fixed in a plastic socket and two
male tabs connected with the thermistor.
14 The resistance of thermistor is in inverse ratio with temperature.
The coolant temperature sensor (CTS) is used for inspecting the coolant temperature of gasoline
engine and transmitting the signal to ECM electronic control unit. Besides calculating the intake
quantity, ECM electronic control unit determines the air-fuel ratio and idling rotating speed according
to coolant temperature and correcting the angle of advance for ignition.
Working voltage: 5V
Resistance under normal temperature (20℃~30℃): 2.26kΩ ~ 3.56kΩ
6. Fault Diagnosis
When the coolant temperature is higher than upper limit or lower than the lower limit of the coolant
temperature sensor (CTS), the fault indicator lamp of the engine will be switched on, the engine will
operate in the fault mode, ECU will ignite and control fuel injection according to the set value of
water temperature in the water temperature fault mode of engine, and the fun will start to operate at
high speed.
7. Troubleshooting
Mainly inspect whether the three wires on the sensor are in short circuit or open circuit with ECU
and instruments.
Inspect whether there is any short circuit, open circuit or grounding in the wire harness of the
sensor. 01
The engine water thermometer will indicate over-high temperature due to the poor grounding of
circuits. 02
03
04
05
06
07
08
09
10
11
12
13
14
MAP/MAT Sensor
1. Appearance
01
02
03
04
05
06 It shall be installed on the left side of intake manifold.
07
08
09
10
The MAP/MAT Sensor installed on the steady pressure cavity of intake manifold is used for
providing the pressure and temperature information for ECM.
12
13 Manifold absolute pressure (MAP) sensor is composed of an elastic diaphragm and a ferromagnetic
core. The diaphragm and a ferromagnetic core which are accurately arranged in the coil will
14 produce a 0~5V output signal in direct ratio with input pressure when any pressure is induced.
Manifold air temperature (MAT) sensor is composed of a thermistor fixed in a plastic socket and two
male tabs connected with the thermistor.
The resistance of thermistor is in inverse ratio with temperature.
Pressure range: 15kPa ~ 102kPa
Working voltage: 5V±0.1V
Working current: 12mA (maximum)
Output impedance: <10Ω
6. Fault Diagnosis
When ECU detects that the output signal of the sensor falls outside its output characteristic curve,
ECU will judge the sensor to have faults, and the fault indicator lamp will be switched on.
7. Troubleshooting
Inspect whether the line connection between the sensor and ECU has any short circuit or open
circuit.
sensor.
Fuel Rail Assembly

1. Appearance
Fuel Rail Assembly
01
Electromagnetic Fuel Injector
Fuel Pressure Regulator
02
03
04
05
2. Mounting Position 06
It shall be installed in the connected position between
intake manifold and cylinder head. 07
08
09
10
11
The fuel rail assembly distributes fuel to the cylinders. During the distribution of fuel, ECM realizes
the purpose of accurate fuel supply through controlling the open time of fuel injector. 13
The fuel injector can duly and accurately inject a suitable quantity of fuel into the intake manifold
according to the ECM signals of gasoline engine. ECM controls the quantity of fuel injection
14
according to the rotating speed of gasoline engine, coolant temperature, intake quantity (intake
pressure) and oxygen content in exhaust.
The fuel pressure regulator is used for regulating the pressure of fuel injection to ensure the
constant pressure difference between the fuel inlet and fuel outlet of fuel injector in the fuel rail.
4. Composition
The fuel rail assembly is composed of a fuel guide rail, a fuel pressure regulator and a fuel injector.
It is installed between the upper and lower parts of intake manifold.
Fuel Rail Assembly:
System resistance to pressure: 750kPa
Electromagnetic Fuel Injector:
Minimum working voltage: 4.5V
Fuel pressure: 300kPa
Coil resistance: 12Ω±0.4Ω
Fuel Pressure Regulator:
Pressure setting: 300kPa
6. Fault Diagnosis
The fuel rail assembly has a lower fault rate. Most faults are fuel leakage of the fuel system resulted
from improper assembly. Therefore, used oil seal mustn’t be reused any more, and some lubricating
oil shall be applied duly while assembling.
01
02
Cautions for Removal and Installation of Fuel Injector:
(a). Remove and install wire harness carefully to avoid damaging terminals.
03
(b). Avoid any liquid from polluting the fuel injector to prevent the short circuit of coil.
(c). Never use any voltage other than the system voltage for test.
04 (d). Never move the package to avoid collision among components.
(e). Install anti-release clips with correct installation tools, otherwise components may be damaged or
05 the fuel control setting may be disordered.
(f). Remove or install one component from or on the packaging plate every time to avoid damage to the
06 key components.
(g). Never reuse any component falling from a higher position because its inside may be damaged or
07 the fuel control setting may be disordered.
Cautions for Removal and Installation of Fuel Rail Assembly:

08 (a). Remove or install carefully to prevent damages of fuel injector, O-ring and fuel injector socket.
(b). Use a new O-ring to prevent fuel leakage while reinstalling the fuel spray nozzle.
09 (c). Tighten the fuel supply and return pipes to the suitable torque to prevent fuel leakage while
installation.
10 (d). Never insert any object into the fuel outlet of regulator to avoid the valve from being jacked away or
damaged and losing its role in regulation accordingly.
11 (e). Never apply excessive side load especially to the electric socket of nozzle, otherwise the pin valve
may be bent to destroy the electromechanical performance.
(f). Never apply excessive force on fuel rail housing while arranging the fuel injector into the intake pipe,
12
otherwise the fuel injector, fuel rail and O-ring may be damaged.
(g). Never immerse the fuel injector in any lubricant to avoid blocking the orifice of fuel injector.
13 (h). Never connect the fuel injector to any power supply above 12V for more than 10s to prevent
damaging the fuel injector.
14 (i). Never apply any non fuel soluble lubricant to the O-ring of fuel injector, otherwise the regulator or
fuel injector may be blocked.
(j). Never adjust the pressure adjusting screws of the fuel pressure regulator, otherwise the fuel
injection will be out of control due to the changed setting of fuel pressure.
Components of Electronic Fuel Injection System

Engine Control Module
1. Appearance 01
02
03
04
05
06
Engine control module (ECM) is installed in the cab.
07
08
09
10
11
Engine control module (ECM) as the core component of the electronic fuel injection system controls 12
the gasoline engine through sensors and actuator. In operation, the sensors transmit various
parameters of operating conditions to ECM, such as intake pressure, coolant temperature, intake 13
temperature, oxygen concentration in waste gas, etc., and ECM will give an instruction to the
actuator after corresponding treatment to regulate the gasoline engine through the actuator. 14
The ECM electronic control unit of gasoline engine is a microprocessor taking a single-chip
microcomputer as the core, and it is composed of a hardware circuit board and control software. It
processes the signals from various sensors, judges the operating conditions of gasoline engine and
sends control signals of optimal fuel injection, ignition, etc. to the actuator, so that the gasoline
engine can be in the optimal operating condition all the time.
Normal working voltage: 9V ~ 16V
Abnormal working voltage: 6.3V ~ 9.0V, 16V ~ 24V
Working temperature: -40℃ ~ 85℃
Overvoltage protection: -12V ~ 24V
6. Fault Diagnosis
ECM electronic control unit has a lower fault rate. If the ECM electronic control unit has any problem,
the lines, sensors and other peripheral components shall be troubleshot firstly, and ECM shall be
replaced after confirming that all the peripheral components do not have any fault.

The installation of ECM electronic control unit requires dustproof and waterproof conditions and
good heat radiation, and its metal housing must be isolated with the vehicle body.
Throttle body Assembly

1. Appearance
01
02
03
04
05
06 It shall be installed in the connected position between
intake manifold and intake pipe.
07
08
09
10
The throttle body assembly is an important component of the electronic fuel injection system, and it
is mainly composed of the throttle body and the valve position sensor (TPS) and idling air control
12 valve (IACV) which are installed on the throttle body.
The throttle position sensor (TPS) is used for measuring the position of throttle and feedback it to
13 ECM so as to control fuel supply.
The idling air control valve (IACV) is mainly used for regulating the idling bypass air amount and
14 controlling the idle speed of gasoline engine so as to ensure the stable operation of gasoline engine
at target idle speed.

The throttle body assembly is mainly composed of the throttle body and the valve position sensor
(TPS) and idling air control valve (IACV) which are installed on the throttle body.
The throttle position sensor (TPS) which is coaxial with accelerator rod and throttle belongs to a
linearly variable resistance structure, and its sliding terminal is driven by the throttle shaft.
The idling air control valve (IACV) is composed of a tapered pin valve pushed by a stepping motor
and a valve seat molded with the throttle body.
Working Parameters for TPS:
Range: 7%~93% opening size
Working voltage: 5V±0.1V
Working Parameters for IACV:
Working voltage: 7.5V~12V
Limiting voltage: 3.5V~14V
Coil resistance: 53Ω±5.3Ω
Coil inductance: 33mH±20%mH
6. Fault Diagnosis
If the throttle assembly has any fault, the indicator lamp of the engine will be switched on. Inspect
whether the line between the sensor and ECU has any short circuit or open circuit.
sensor. 01
7. Cautions for Removal and Installation 02

(a). Remove and install wire harness plug carefully to avoid damaging terminals.
(b). Avoid the surface of throttle body from contact with liquid pollutant.
03
(c). Never store the throttle body without a protective hat. The normal function of throttle body will be
affected in case of contact with pollutant.
(d). Never adjust the adjusting screws for throttle body cable support. Any change in default value will 04
result in the disturbance of system function.
(e). Never use the voltage other than that regulated by system for test, otherwise the throttle body will be 05
damaged.
(f). Install anti-release clips with correct installation tools, otherwise components may be damaged or 06
the fuel control setting may be disordered.
07
08
09
10
11
12
13
14
Oxygen Sensor
1. Appearance
01
02
03
04
05
It shall be installed at the tip of exhaust manifold.
06
07
08
09
10
11 The oxygen sensor is an important component of closed-loop control system. It is installed at the
outlet of exhaust pipe and provides the signal of oxygen concentration in mixed gas for correct the
12 quantity of fuel injection so as to realize the closed-loop control of air-fuel ratio.
The oxygen sensor has the working process that the zirconia component is heated and activated,
air enters into the central position (electrode) of the zirconia component, the exhaust passes
13
through the outer electrode of the zirconia component, oxide ions migrate from the center to the
outer electrode of the zirconia component, and a simple primary battery is formed accordingly;
14 voltage will generate between the two electrodes, and the oxygen sensor can change the output
voltage according to the oxygen content in the exhaust.

The oxygen sensor is a ceramic tube with pores. The tube wall is surrounded by engine exhaust
externally and ventilated by air internally.
Working principle of oxygen sensor: When temperature is higher than 300℃, zirconia component
can separate oxide ions from oxygen in the exhaust passing through it; in such case, a potential
difference will be produced inside and outside the sensor due to the different oxygen contents, the
difference of oxygen contents in the two environments (air side and exhaust side) can be obtained
by measuring the potential difference, the information will be then transmitted to ECM electronic
control unit, and ECM electronic control unit with regulate the mixed gas by controlling the quantity
of fuel injection of the fuel injector so as to approach the air-fuel ratio of the mixed gas to the
theoretical value.
Working temperature: 260℃~850℃
Maximum overheating temperature: 930℃
6. Fault Diagnosis
When the oxygen sensor has any fault, firstly, inspect whether the wire harness of the oxygen
sensor is well connected and whether there is any short circuit or open circuit; secondly, inspect
whether the oxygen sensor is damaged. The damage of oxygen sensor is generally resulted from
lead and phosphorus poisoning, so it is prohibited to use leaded gasoline. Besides, the
over-consumption of engine oil by the engine can also easily lead to the fault of oxygen sensor.

(a). Avoid oxygen sensor from colliding with hard objects or falling from a higher position. Violent
vibration may result in the damages of ceramic components or heating components.
(b). Avoid sensor from being polluted by carbon deposits, silicone oil, engine oil, lead, paint or other
organic matters, etc. Pollutant will affect the signal output of sensor and may result in permanent 01
damage.
(c). Never pull the conducting wire of sensor. Excessive pulling may damage the reliable connection of 02
the conducting wire and affect the normal use of sensor.
(d). Avoid knotting, folding or other operations capable of damaging the harness conducting wire of
03
sensor.
(e). Never apply grease, cleaning agent or other foreign matters on connectors. These substances can
result in the fault of sensor. 04
(f). Never use any welding flux on the conducting wire or harness of sensor. Please use special
shrinkable pipes for Delphi packaging. Never try to repair the conducting wire of sensor. 05
(g). Tighten the oxygen sensor to the specified torque to avoid the problems of durability, exhaust
leakage, removal difficulty, etc. 06
(h). Never use any liquid while installing plugs so as to prevent air pollution.
(i). Slightly heat the exhaust system so as to remove sensor easily. The heating temperature shall not 07
be too high to avoid influence on safety in operation.
(j). Apply anti-seize in thread areas for reducing the damage to threads in the process of removal.
(k). Clean the foreign matters on the mounting holes of sensor to avoid sintering resulted from the 08
installation of new sensor.
(l). If the removed has to be installed on the gasoline engine again, replace the washer and apply 09
anti-sintering compound on threads again.
10
11
12
13
14
Lubrication System
Lubrication System.......................................................11-1
Flow Chart ................................................................11-1 01
Part Drawing.............................................................11-2
Oil Pump ......................................................................11-4 02
Overhaul ...................................................................11-4
Oil Filter........................................................................11-9 03
Overhaul ...................................................................11-9
Inspection of Oil Pressure ..........................................11-10
04
Adjustment of Oil Pressure ........................................11-11
05
06
07
08
09
10
11
12
13
14
Lubrication System - Lubrication System 11-1
Lubrication System
Flow Chart
Piston and Cylinder Wall Central Camshaft Journal #3 01
02
Small End of Connecting Rod
Rocker Arm Shaft 03

Big End of Connecting Rod
04
Rocker Arm
Crankshaft Journal 05
06
Oil Hole of Cylinder Camshaft Journal #1,2
07
Oil Filter Bypass valve

Camshaft Journal #5
08
09
Oil Pump Safety Valve Central Hole of
Camshaft 10
Cylinder Wall
Oil Filter 11
12
13
14
Engine Oil
11-2 Lubrication System - Lubrication System
Part Drawing
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Lubrication System - Lubrication System 11-3
01
02
03
04
05
06
07
08
09
10
11
12
1 Shouldered Tap Bolt, Oil Pump Assembly 11 A-shaped Combined Gasket
2 Shouldered Tap Bolt, Oil Pump Assembly 12 Discharge Bolt 13
3 Shouldered Tap Bolt, Oil Pump Assembly 13 Hexagon Bolt with Flange
4 Oil Pump Assembly 14 Connecting Pipe 14
Locating Bush, Crankshaft Rear End Cover of
5 15 Oil Filter Assembly
Oil Pump
6 Oil Pump Gasket 16 Hexagon Bolt
7 Long Dipstick Assembly 17 Spring Gasket
8 Dipstick Guide Pipe 18 Oil Filter Assembly
9 Oil Pan Gasket 19 O-ring for Pipe Joint
10 Oil Pan Assembly
11-4 Lubrication System - Oil Pump
Oil Pump
Overhaul
1. Remove Oil Pump Assembly (Refer to Chapter 07 Disassembly of Engine -- Oil Filter and Oil
01 Pump, Removal)
02 2. Remove Oil Pump

(a). Remove oil pump cover.
03
04
05
06
07
(b). Remove internal gear.
08
09
10
11
12
(c). Remove external gear.
13
14
(d). Remove valve cap of oil pump pressure limiting

valve.
Lubrication System - Oil Pump 11-5
(e). Take out oil pump pressure limiting valve spring and
oil pump pressure limiting valve plunger.
01
02
03
04
3. Detect Oil Pump
(a). Detect the radial clearance between internal gear and 05
crescent.
Standard: 0.60～0.80mm 06
07
08
09
(b). Detect the radial clearance between external gear
and crescent. 10
Standard: 0.25～0.40mm
11
12
13
14
(c). Detect the radial clearance between external gear

and pump body.
Limit: 0.3mm
(d). Detect side clearance.

Decide the side clearance with a knife straight edge
according to the thickness between knife straight
edge and gear.
Side Clearance Limit: 0.17mm
(e). Detect the wear of oil pump pressure limiting valve

plunger. Replace the plunger in case of serious wear.
01
02
03
04
(f). Detect whether the elasticity of oil pump pressure
05 limiting valve spring is too soft. Replace the oil pump
pressure limiting valve spring if it is too soft.
06
07
08
09
4. Assemble Oil Pump
10 (a). Assemble the oil pump pressure limiting valve
plunger and spring in order.
11 Tip:
Clean the removed components while assembling oil
12 pump.
13
14
(b). Install and fasten the valve cap of oil pump pressure
limiting valve.
(c). Install external gear.

Lubrication System - Oil Pump 11-7
(d). Install internal gear.
01
02
03
04
Caution:
The dot mark on the external gear shall face outwards 05
while installing the external gear.
06
07
08
09
(e). Drop engine oil into internal and external gears.
10
11
12
13
14
(f). Install oil pump cover.
(g). Inspect installed internal and external gears. The

gears shall rotate normally without obstruction.
5. Install Oil Pump Assembly (Refer to Chapter 08 Assembly of Engine -- Crankshaft Rear End
Cover and Oil Pump, Installation)
Caution:
01 Use a new gasket and apply HZ-RTV sealant on the
gasket while installing oil pump on crankcase.
02 Lubricate the front sealing opening with lubricant
before installing oil pump.
03
04
05
06
07
08
09
10
11
12
13
14
Lubrication System - Oil Filter 11-9
Oil Filter
Overhaul
1. Replace Oil Filter Assembly According to the 01
Following Time.
02
First Replacement After 1,000km
Time Interval for Later
After Every 10,000km 03
Replacement
Caution: 04
• Replace oil filter irregularly if it is dirty.
• Inspect oil filter regularly. If necessary, remove
05
the dirt blocking the filter screen and clean the
filter screen.
06
07
08
09
10
11
12
13
14
11-10 Lubrication System - Inspection of Oil Pressure
Inspection of Oil Pressure

Tip:
During idling and operation of engine, oil pressure light shall be fully extinguished. If it is not extinguished,
01 oil pressure shall be inspected according to the following methods:
1. Inspect Engine Oil Level in Oil Pan

02
Pull out the dipstick to inspect whether the oil level is
High Level lower than the low level line of the dipstick. If the oil
03 Line
level is lower than the low level line, add engine oil
into oil pan to elevate it above the low level line but
04 never higher than the high level line.
05 Low Level
Line
06
07 2. Inspect Oil Filter

• The oil filter must be clean without any blockage.
08 3. Inspect Engine
• Make sure no oil leakage in any position of the
09 engine.
4. Detect the Oil pressure at Oil Pressure Warning
Unit
10 (a). Remove the oil pressure warning unit installed on the
main oil gallery on one side of the crankcase oil filter.
11 (b). Install joints for pressure gauge in the screwed hole
of oil pressure warning unit. Install pressure gauge.
12 (c). Start the engine and idle it until the coolant
temperature rises to 75℃~85℃. At this temperature,
13 increase the rotating speed of engine to 3000r/min
and read the reading of the pressure gauge.
Normal oil pressure:
14
294.20~441.30kPa at 3000r/min.
• If the readings of the pressure gauge can not reach
the range of normal values, the oil pump must be
inspected.
Caution:
While installing the oil pressure warning unit, the
threads must be wrapped by a seal tape, the oil
pressure warning unit shall be tightened with the
torque of 11.77~14.71N·m.
Lubrication System - Adjustment of Oil Pressure 11-11
Adjustment of Oil Pressure

1. Remove Oil Pan Assembly (Refer to Chapter 07 Disassembly of Engine – Flywheel and Oil
Pan, Removal)
01
2. Remove valve cap of oil pump pressure limiting
valve.
High Level 02
Line
03
04
Low Level
Line 05
06
3. Lower Oil Pressure
Tip: 07
In case of lower oil pressure, add a proper gasket
between the valve cap of oil pump pressure limiting valve 08
and oil pump pressure limiting valve spring so as to
increase the elasticity of oil pump pressure limiting valve 09
spring.
Caution:
Replace the oil pump pressure limiting valve spring if 10
it is too soft.
11
4. Higher Oil Pressure 12

Tip:
In case of higher oil pressure, add a proper gasket on the
contact surface between the valve cap of oil pump 13
pressure limiting valve and oil pump so as to weaken the
elasticity of oil pump pressure limiting valve spring. 14
11-12 Lubrication System - Adjustment of Oil Pressure
5. After adding the suitable gasket, install the valve

cap of oil pump pressure limiting valve and screw
it to the standard level.
01
02
03
04
05
06
07 6. Install Oil Pan Assembly (Refer to Chapter 08 Assembly of Engine -- Oil Filter and Oil Pan,
Installation)
08 7. Start the engine and inspect the oil pressure.
Tip:
09 Under normal engine temperature, observe whether the oil pressure meets the standard or not.
Otherwise, readjust the oil pressure according to the above methods.
10
11
12
13
14
Cooling System
Cooling System ............................................................12-1
General.....................................................................12-1 01
Part Drawing.............................................................12-2
Thermostat ...................................................................12-4 02
General.....................................................................12-4
Overhaul ...................................................................12-5 03
Pulley and Drive Belt..................................................12-10
Overhaul .................................................................12-10
04
Water Pump ...............................................................12-14
Overhaul .................................................................12-14
Inlet Hose Assembly ..................................................12-18 05
Overhaul .................................................................12-18
06
07
08
09
10
11
12
13
14
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Cooling System - Cooling System 12-1
Cooling System
General
1. Cooling system is used for keep the engine in suitable temperature range under all the operating
conditions. The cooling system shall prevent the engine from overheating and undercooling. The 01
cooling system shall ensure the engine after cold start to warm up quickly so as to reach normal
working temperature as soon as possible. 02
2. Cooling system of a forced circulation water-cooled type is composed of a heat radiator, a water
pump, a fun, a Thermostat, a wind scooper, etc. 03
3. Water pump shaft adopts shaft bearing as the support, and graphite ceramic water seal is used. The
water pump is driven by crankshaft pulley and water pump belt.
04
While in use, when the water seal is damaged and the drain hole under the water pump body drips
seriously, the water seal shall be replaced and it is not allowed to block the drain hole during water
leakage, otherwise water will enter the bearing and result in the wear of bearing soon. The bearing 05
shall be replaced in case of abnormal noise during operation.
4. The tensioning of water pump belt shall be regularly inspected and adjusted as required by 06
“technical maintenance”. The water pump belt shall be adjusted by the methods of pressing the belt
between the water pump pulley and generator pulley manually and the pressed distance of 07
10~15mm is preferable.
08
09
10
11
12
13
14
12-2 Cooling System - Cooling System
Part Drawing
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Cooling System - Cooling System 12-3
1 Fan Belt 6 Water Pump Gasket

Combination of Hexagon Bolt, Spring Washer
2 7 Hexagon Nut with Flange
and Flat Washer
3 Water Pump Pulley 8 Bolt Assembly
01
4 Shouldered Tap Bolt for Oil Pump Assembly 9 Thermostat Cover
5 Water Pump Assembly 10 Thermostat Assembly
02
03
04
05
06
07
08
09
10
11
12
13
14
12-4 Cooling System - Thermostat
Thermostat
General
1. Thermostat controls the engine coolant temperature of. When the coolant temperature is lower than
01 working temperature, the engine coolant flows back to the water pump inlet through bypass. As
soon as the engine coolant temperature reaches the operating range, the thermostat is started and
02 the bypass is closed so as to force the engine coolant to flow into heat radiator or heat exchanger.
2. The incorrect specification or fault of thermostat may result in the overheating or undercooling of
03 engine operation.
3. Never operate the engine under the condition of without any thermostat. Without Thermostat, the
path with the minimum resistance for coolant is to flow into the water pump inlet through the bypass,
04
and engine overheating will be caused as a result.
05
06
07
08
09
10
11
12
13
14
Cooling System - Thermostat 12-5
Overhaul
1. Remove Thermostat
(a). Remove the fixing bolts for thermostat with a wrench.
01
• Take out flat washer.
• Take out hexagon bolt.
• Take out spring washer. 02
03
04
05
06
07
08
(b). Remove the thermostat cover.
09
10
11
12
13
14
(c). Pull out the thermostat.

2. Clean and Inspect for Continuous Usage

(a). Inspect whether the outside of thermostat is
damaged.
Inspect whether there is any crack, embedded debris,
01 loss of one-way valve ball, damage of base and other
damage.
02 • Replace the thermostat in case of any damage.
03
04
(b). Inspect whether any gasket adheres to the contact
05 surface between Thermostat housing and thermostat
cover.
06 • Any gasket shall be removed with a shovel.
07
08
09
10
11
12
(c). Clean the installing surface of thermostat housing.
13
14
(d). Inspect whether there is any crack or other damage

on the installing surface of thermostat housing.
• Replace the thermostat housing in case of crack
or other damages.
01
02
03
04
05
06
3. Measure 07
(a). If it is doubted that the thermostat has any fault,
measure the starting temperature of the thermostat, 08
and put the thermostat and a thermometer with the
measuring range of 100°C in a container filled with 09
water.
Caution: 10
Never make the thermostat or thermometer get
contact with the container.
11
12
(b). Heat water and inspect thermostat according to the
following steps.
13
• Heat water in the container to 90℃ or above by
observing the thermometer to start the
thermostat automatically. 14
• If the thermometer is not started even though
water in the container is heated to 90℃ or
above, it indicates damage or incorrect model of
thermostat, and it shall be replaced.
Caution:
Standard working temperature is marked on the
thermostat. Confirm the correct parts information and
data for installing thermostat.
4. Install Thermostat
(a). Apply sealant on the installing surface of thermostat
housing.
01
02
03
04
05
06
07 (b). Install the thermostat.
08
09
10
11
12
13
14
(c). Close the thermostat cover.

Tip:
It is necessary to apply sealant on the installing surface of
thermostat cover.
(d). Install and fasten fixing bolts for the thermostat cover.
01
02
03
04
05
06
07
08
09
10
11
12
13
14
12-10 Cooling System - Pulley and Drive Belt
Pulley and Drive Belt

Overhaul
01 1. Remove Drive Belt
(a). Loosen the adjusting bolts for generator upper
02 support.
03
04
05
06
07
08
09 (b). Push the generator upwards and remove the

generator belt as soon as it is loosened.
10
11
12
13
14
(c). Inspect whether the drive belt is damaged. It must be

replaced in case of damage.
Cooling System - Pulley and Drive Belt 12-11
2. Remove Water Pump Belt

(a). Remove four fixing bolts for the water pump pulley.
Tip:
While removing water pump pulley, it is necessary to
insert a rubber rod or wood rod between the water pump 01
pulley and crankshaft pulley so as to prevent the water
pump pulley to rotate along with the bolts being removed. 02
03
04
05
06
(b). Remove the water pump pulley. 07
08
09
10
11
12
13
14
3. Inspect Water Pump Pulley
(a). Clean the water pump pulley with solvent, acidic or
alkaline substances.
Caution:
use, carefully read the manual of the
manufacturer.
(b). Wipe of the dirt on the surface of water pump pulley.

12-12 Cooling System - Pulley and Drive Belt
(c). Dry the water pump pulley with compressed air.

Caution:
01 Flying debris and dirt can result in personal injury.
02
03
04
(d). Inspect whether the water pump pulley has any crack
05 or damage. Replace it in case of any damage.
06
07
08
09
4. Install Water Pump Pulley
10 (a). Put water pump pulley in the mounting position.
11
12
13
14
(b). Install and fasten the fixing bolts for water pump
pulley.
Tip:
It will be more convenient to fasten the fixing bolts for
water pump pulley after the water pump belt is installed.
Cooling System - Pulley and Drive Belt 12-13
(c). Push the generator assembly upwards and sheathe

the belt.
01
02
03
04
05
06
(d). Install the adjusting bolt at the upper end of the 07

generator.
Tip: 08
Press down the generator to tension the generator belt to
a suitable position. Fasten the adjusting bolts for 09
generator.
10
11
12
13
14
(e). Inspect whether the generator is suitably installed.

• Press down the belt in the middle between
generator and water pump pulley to inspect
whether the belt meets the requirement or not.
Strength: 98N
Reduction: 10~15mm
12-14 Cooling System - Water Pump
Water Pump
Overhaul
01 1. Primarily inspect the engine operate at idle
speed. Inspect whether the water pump has water
02 leakage or not.
03
04
05
06
07
08
09 2. Remove Water Pump Pulley and Crankshaft Pulley (Refer to Chapter 07 Disassembly of
Engine -- Water Pump Pulley and Crankshaft Pulley, Removal)
10 3. Remove Front Cover and Timing Belt (Refer to Chapter 07 Disassembly of Engine -- Front
11
5. Remove Camshaft and Timing Gear Rear Cover (Refer to Chapter 07 Disassembly of Engine
12 -- Camshaft Timing Gear and Rear Cover, Removal)
13 6. Remove Water Pump Assembly

(a). Remove the fixing bolts for water pump.
14
Cooling System - Water Pump 12-15
(b). Remove water pump assembly.
01
02
03
04
05
06
7. Clean and Inspect for Continuous Usage 07

(a). Clean the water pump with solvent, acidic or alkaline
substances. 08
Caution:
• The cleaning by solvents and acid or alkaline 09
proposal from the manufacturer. 10
• Some solvents are inflammable and toxic. Before 11
manufacturer. 12
(b). Clean dirt on the water pump with a hairbrush. 13
14

Caution:
12-16 Cooling System - Water Pump
(d). Inspect whether there is any crack on the water

pump. Replace the damaged components.
01
02
03
04
(e). Inspect whether the water pump fan blade has any
05 pitting and breakage. It must be replaced in case of
damage.
06
07
08
09
8. Install Water Pump Assembly
10 (a). While installing water pump, install water pump
gasket firstly and apply sealant. Apply GY-340
11 anaerobic adhesive on the fixing bolts for water pump
assembly. Install rear cover spongy gasket, etc.
12
13
14
(b). Put the water pump assembly in the mounting

position.
Cooling System - Water Pump 12-17
(c). Install and fasten the fixing bolts for water pump
assembly.
Tip:
Fasten all the bolts diagonally one by one.
01
02
03
04
05
06
9. Install Rear Cover and Camshaft Timing Gear (Refer to Chapter 08 Assembly of Engine -- 07
10. Install Crankshaft Timing Pulley, Tensioner Pulley (Refer to Chapter 08 Assembly of Engine 08
-- Crankshaft Timing Pulley and Tensioner Pulley, Installation)
11. Install Timing Belt and Front Cover ((Refer to Chapter 08 Assembly of Engine -- Timing Belt 09
12. Install Crankshaft Pulley and Water Pump Pulley ((Refer to Chapter 08 Assembly of Engine -- 10
11
12
13
14
12-18 Cooling System - Water Hose Assembly
Water Hose Assembly

Overhaul
01 1. Remove Water Hose Assembly
(a). Remove two fixing bolts for water hose.
02
03
04
05
06
07
08
09 (b). Remove the water hose Assembly.
10
11
12
13
14
2. Clean and Overhaul Water Hose

(a). Clean the water hose with solvent, acidic or alkaline
substances.
Caution:
manufacturer.
Cooling System - Water Hose Assembly 12-19
(b). Clean dirt on the water hose with a hairbrush.
01
02
03
04
Caution: 05
while using compressed air. 06
07
08
09
(d). Inspect whether the water hose has any crack.
Replace it in case of damage. 10
11
12
13
14
(e). Inspect whether the water hose gasket has any

crack. Replace it in case of damage.
12-20 Cooling System - Water Hose Assembly
3. Install Water Hose Assembly

(a). Put the water hose assembly in the mounting
position.
01
02
03
04
05
06
07 Caution:
While installing water hose, install the water hose
08 gasket and apply sealant firstly.
09
10
11
12
(b). Install and fasten the fixing bolts for water hose
assembly.
13
Tip:
The screwed holes of the fixing bolts for water hose
14 assembly are communicated with the inside of cylinder
head. Therefore, GY-340 anaerobic adhesive or
equivalent must be applied before installing the two bolts.
Intake/Exhaust System
Intake System ..............................................................13-1
General.....................................................................13-1 01
Part Drawing.............................................................13-2
Intake Manifold.............................................................13-3 02
Overhaul ...................................................................13-3
Exhaust System .........................................................13-15 03
General...................................................................13-15
Part Drawing...........................................................13-16
04
Exhaust Manifold........................................................13-18
Overhaul .................................................................13-18
05
06
07
08
09
10
11
12
13
14
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Intake/Exhaust System - Intake System 13-1
Intake System
General
1. The intake system mainly includes a high-level intake pipe assembly, an air filter, an intake manifold
and relevant hoses, and it provides pure air for cylinders. 01
2. The intake manifold distributes clean air to the intake channel of the cylinders. A preheating plug as
an auxiliary starting device is installed on the intake pipe and used for elevate the temperature of 02
combustion chamber during the cold start of the engine.
03
04
05
06
07
08
09
10
11
12
13
14
13-2 Intake/Exhaust System - Intake System
Part Drawing
01
02
03
04
05
06
07
08
09
10
11
12
13
14
1 Valve EGR 11 Intake MAT/MAP Sensor

2 Lifting Hook 12 Clip Support
3 Water Temperature Sensor 13 Clip for Return Water Rubber Hose
4 Coolant Temperature Sensor 14 Intake Manifold Gasket
5 Support for Intake MAT/MAP Sensor 15 Intake Manifold Component
6 Throttle Body Assembly 16 PCV Valve
Support for Charcoal Canister Cleaning
7 17 PCV Valve Breather
Electromagnetic Switch
8 Thermostat Cover 18 Three-Way Pipe
9 Breather of Valve EGR 19 Return Water Rubber Hose
10 Bolt Assembly 20 Crankcase Breather
Intake/Exhaust System - Intake Manifold 13-3
Intake Manifold
Overhaul
1. Remove Intake Manifold 01
(a). Disconnect crankcase breather from cylinder head
cover. 02
• Loosen the clamp.
• Pull out the hose. 03
04
05
06
07
08
(b). Disconnect return water rubber hose from water hose 09

assembly.
• Loosen the clamp. 10
• Pull out the hose.
11
12
13
14
(c). Remove the fixing bolts at the lower end of intake

manifold.
13-4 Intake/Exhaust System - Intake Manifold
(d). Remove the fixing nuts for connecting intake manifold

with cylinder head.
01
02
03
04
05
06
07 (e). Remove intake manifold assembly.
08
09
10
11
12
13
14
2. Remove Intake Manifold

(a). Loosen the clip for return water rubber hose and
disconnect Valve EGR breather from throttle body
Assembly.
(b). Loosen the clip for return water rubber hose and
disconnect Valve EGR breather from Valve EGR.
(c). Switch on charcoal canister cleaning electromagnetic

switch and remove Valve EGR.
Tip:
While switching on the charcoal canister cleaning
electromagnetic switch, it can be switched on by using a 01
screwdriver or equivalent tool under the support for
charcoal canister cleaning electromagnetic switch, so that 02
Valve EGR can be removed.
03
04
(d). Remove the fixing bolts for throttle body assembly
with a torque wrench or equivalent tool. 05
06
07
08
09
(e). Remove the throttle body assembly.
10
11
12
13
14
(f). Disconnect the vacuum pipe of oil pressure regulator

from intake manifold.
(g). Loosen the clip for PCV valve breather. Pull out the
three-way pipe.
(h). Loosen the clip for return water rubber hose and take
out the return water rubber hose.
01
02
03
04
(i). Remove the fixing bolts for thermostat cover with a
05 wrench.
• Take out flat washer.
06 • Take out hexagon bolt.
• Take out spring washer.
07
08
09
(j). Remove the thermostat cover and pull out the
10 thermostat.
11
12
13
14
(k). Remove the bolt for MAP sensor with a wrench.
(l). Remove the support for MAT sensor and MAP/MAT

sensor.
(m). Remove the water temperature sensor with a long

sleeve.
01
02
03
04
(n). Remove the coolant temperature sensor with a long
sleeve. 05
06
07
08
09
3. Clean and Inspect Components
(a). Clean the sealing surface between cylinder head and 10
intake pipe.
Tip: 11
While inspecting intake manifold, the contact surface
between intake manifold and cylinder head is very 12
important, and it is necessary to inspect the surfaces on
cylinder head in contact with intake pipe at the same time. 13
Caution:
Never clear away carbon with sharp tools randomly.
14
Never abrade or scratch metal surfaces while clearing
carbon.
(b). Clean the carbon deposits on the sealing surface

between intake pipe and cylinder head with a
hairbrush.
(c). Blow out the foreign matters with compressed air.

Caution:
(d). Clean intake manifold with solvent, acidic or alkaline

substances.
Caution:
01 substances shall be subject to the usage
02 • Goggles and protective clothing shall be worn to
03 • Some solvents are inflammable and toxic. Before
manufacturer.
04
(e). Clean the carbon deposit on the intake manifold with
05 a hairbrush.
06
07
08
09
10 (f). Dry it with compressed air.

Caution:
11
12
13
14
(g). Clear the sealing surface between intake pipe and

cylider head with a shovel.
(h). Blow of the carbon deposit and dirt in the intake

manifold with compressed air.
Caution:
(i). Inspect intake pipe joint. Crack or serious defect is

not acceptable. It must be replaced in case of serious
damage.
01
02
03
04
(j). Inspect the flatness of the connecting surface
between intake pipe and cylinder head with a knife 05
ruler and a feeler gauge.
06
07
08
09
4. Assemble Intake Manifold
(a). Put the throttle body assembly in the mounting 10
position.
11
12
13
14
(b). Install the fixing bolts for throttle body assembly with
a torque wrench.
(c). Install valve EGR from the lower end of the support
for charcoal canister cleaning electromagnetic switch.
(d). While installing valve EGR breather, sealant must be

applied on the valve EGR breather firstly.
01
02
03
04
(e). Loosen the clip for valve EGR breather. Connect the
05 valve EGR breather with throttle body assembly.
06
07
08
09
(f). Loosen the clip for valve EGR breather. Connect the
10 valve EGR breather with Valve EGR.
11
12
13
14
(g). While installing vacuum connecting pipe, sealant

must be applied on the vacuum connecting pipe
firstly.
(h). Connect the vacuum connecting pipe with intake

manifold.
(i). While installing crankcase breather, sealant must be

applied on the crankcase breather firstly.
01
02
03
04
(j). Loosen the clip for PCV valve breather. Install
three-way pipe. 05
06
07
08
09
(k). While installing return water rubber hose, sealant
must be applied on the return water rubber hose 10
firstly.
11
12
13
14
(l). Loosen the clip for return water rubber hose. Install
the return water rubber hose.
(m). Put MAP/MAT sensor and the support in the

mounting positions.
(n). Install the bolts for MAP/MAT sensor with a wrench.
01
02
03
04
(o). Install the water temperature sensor with a long
05 sleeve.
06
07
08
09
(p). Install the coolant temperature sensor with a long
10 sleeve.
11
12
13
14
5. Install Intake Manifold Assembly

(a). Put intake manifold assembly in the mounting
position.
Tip:
Replace intake manifold gasket.
(b). Install and fasten the fixing bolts and nuts for intake
manifold.
Tip:
Nuts shall be fastened diagonally in alternation.
01
02
03
04
05
06
(c). Install and fasten the fixing bolts at the lower end of 07
intake manifold.
08
09
10
11
12
13
14
(d). Install return water rubber hose on water hose.

Tip:
While installing return water rubber hose, it is more
convenient to apply sealant on the inner wall of rubber
hose opening, and better sealing can be obtained.
(e). Install crankshaft rubber breather on cylinder head

cover.
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Intake/Exhaust System - Exhaust System 13-15
Exhaust System
General
The exhaust system is composed of a exhaust manifold, a welded assembly muffler and exhaust pipe,
and other relevant lifting ear supports, and it is used for reducing exhaust noise and exhaust energy. 01
02
03
04
05
06
07
08
09
10
11
12
13
14
13-16 Intake/Exhaust System - Exhaust System
Part Drawing
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Intake/Exhaust System - Exhaust System 13-17
Stud Bolt, for Connection of Exhaust Manifold

1 Heat Shield Assembly, Exhaust Pipe 7
and Muffler
2 Internal Screen Assembly, Exhaust Pipe 8 Baseplate, Exhaust Manifold Cover
3 Hexagon Nut with Flange M6 9 Stud Bolt
01
4 Shouldered Tap Bolt, Cylinder Head Cover 10 Hexagon Nut, I Type
5 Heated Oxygen Sensor 11 Stud Bolt, Exhaust Manifold
02
6 Exhaust Manifold Assembly
03
04
05
06
07
08
09
10
11
12
13
14
13-18 Intake/Exhaust System - Exhaust Manifold
Exhaust Manifold
Overhaul
01 1. Remove Exhaust Manifold Thermal Baffles
(a). Unscrew the fixing nuts for the upper heat shield of
02 exhaust manifold.
03
04
05
06
07
08
09 (b). Remove the upper heat shield of exhaust manifold.
10
11
12
13
14
(c). Remove the fixing bolts for the lower heat shield of
exhaust manifold. Remove the lower heat shield of
exhaust manifold.
Intake/Exhaust System - Exhaust Manifold 13-19
2. Remove Exhaust Manifold

(a). Remove the fixing nuts for exhaust manifold.
01
02
03
04
05
06
(b). Remove exhaust manifold. 07
08
09
10
11
12
13
14
(c). Remove the heat shield for intake manifold gasket.

3. Clean and Inspect Exhaust Manifold

(a). Clean the sealing surface between cylinder head and
exhaust pipe with a shovel and a piece of clean cloth.
Caution:
01 Never discharge any sealing material or other dirt and
debris into the exhaust hole.
02
03
04
(b). Blow out the carbon deposits inside the cylinder head
05 with compressed air.
Caution:
06 Suitable goggles and a protective mask shall be worn
07
08
09
(c). Clean the sealing surface between exhaust pipe and
10 cylinder head with a shovel.
11
12
13
14
(d). Blow out the carbon deposits inside the exhaust pipe
with compressed air.
Caution:
(e). Inspect whether the connected sealing surface

between the exhaust pipe and the cylinder head has
any crack. Replace it in case of damage.
(f). Clean the sealing surface of the exhaust pipe and

exhaust pipe joint with a shovel.
01
02
03
04
(g). Blow out the carbon deposits inside the exhaust pipe 05
joint with compressed air.
Caution:
06
Flying debris and dirt can result in personal injury. 07
08
09
(h). Inspect whether the connected sealing surface 10

between the exhaust pipe and its joint has any crack.
Replace it in case of damage. 11
12
13
14
(i). Inspect the flatness of installing surface of exhaust

pipe with a knife ruler and a feeler gauge. If the
unevenness exceeds the technical range, the
exhaust pipe shall be machined or replaced.
4. Install Exhaust Manifold Assembly

(a). Install the internal screen assembly of exhaust
manifold.
01
02
03
04
05
06
07
(b). Put the exhaust manifold in the mounting position.
08
09
10
11
12
13
14
(c). Install and fasten the fixing nuts for exhaust manifold.
Tip:
The nuts shall be fastened diagonally in alternation.
(d). Install the lower heat shield pad of exhaust manifold.

• Install and fasten the fixing nuts for heat shield
pad.
01
02
03
04
05
06
(e). Install the upper heat shield pad of exhaust manifold. 07
08
09
10
11
12
13
14
(f). Install and fasten the fixing nuts for the upper heat
shield pad of exhaust manifold.
- Memo -
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Electric Equipment System
Generator .....................................................................14-1
General.....................................................................14-1 01
Part Drawing.............................................................14-2
Generator Test .........................................................14-3 02
Removal and Installation of Generator .....................14-6
Starter ........................................................................14-12 03
General...................................................................14-12
Part Drawing...........................................................14-13
04
Starter Test.............................................................14-14
Removal and Installation of Starter.........................14-17
05
06
07
08
09
10
11
12
13
14
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Electric Equipment System - Generator 14-1
Generator
General
Generator is the main power supply for automobile electric equipment. During the normal operation of
automobile, the generator not only supplies power for the electrical equipment except starter, but also 01
charges the battery.
Attentions shall be paid to the following issues in the process of usage and maintenance of AC 02
generator:
1. The earth of battery and the polarity of AC generator must be consistent and shall be negative earth, 03
otherwise the battery will discharge greatly through the silicon rectifier diode of generator and burn
out the diode as a result.
04
2. Never judge whether the generator generates or not by the method of transiently grounding
(earthing) the output terminal of the generator (trying to ignite).
3. Never remove battery and other main electric equipment during the operation of generator at high 05
speed so as to avoid the occurrence of transient over-voltage which will damage diode, regulator or
other electric equipment. 06
4. The connecting wire between generator and battery shall be inspected frequently to ensure the firm
and reliable connection. 07
5. The tensioning degree of the generator pulley shall be inspected frequently to ensure it meets the
requirements while leaving factory. Over-loose belt will result in the undercharge of battery, while 08
over-tight belt will easily damage the belt and generator bearing.
6. The generator which operates abnormally shall be duly inspected so as to find out the faults and
troubleshoot. 09
7. The generator shall be maintained regularly. Generally, the wearing elements of the generator, such
as electric brush, rectifying elements, regulator, bearing, etc., shall be subject to an inspection and 10
necessary tests after 75 hours of operation or 30,000km of traveling for automobile.
11
12
13
14
14-2 Electric Equipment System - Generator
Part Drawing
01
02
03
04
05
06
07
08
09
10
11
12
13
14
1 Generator Upper Support 3 Generator Lower Support

2 Generator
Generator Test
1. Test of Generator Output DC Voltage
(a). Start the engine and operate it in the idling state.
01
(b). Measure the voltage at both terminals of the battery
with a digital multimeter. The voltage readings shall
be within the range of 13~15V (depending on the 02
setting value of the regulator). When the rotating
speed of the generator is increased, the output DC 03
voltage of the generator shall generally remain
unchanged. 04
05
2. AC Component Test of Generator Output Voltage
Connect the AC voltage position of the digital multimeter with the positive and negative terminals of the 06
battery in parallel to measure the output AC voltage of generator (the normal value shall be no more than
0.4V). 07
The specific steps are as follows:
(a). Start the engine and operate it at the rotating speed of 2000rpm; 08
(b). Switch on the headlights and apply certain load to the generator;
(c). Connect the digital multimeter with the positive and
negative terminals of the battery in parallel and read 09
the AC voltage value. If the voltage ≤0.4V, it indicates
the rectifier of generator operates normally. If the 10
voltage > 0.5V, it indicates that the rectifier of the
generator has certain faults. 11
12
13
3. Voltage Drop Test of Charging System 14

The voltage drop test is mainly used for judging whether the connecting wire between the generator and
the battery is well connected. The specific steps are as follows:
(a). Start the engine and operate it at the rotating speed of 2000rpm[
(b). Switch on the headlights and apply certain load to the generator;
(c). Measure the voltage drop between the output terminal of the generator and the positive terminal of
the battery with the DC voltage position of the digital multimeter. The normal voltage value shall be
no more than 0.4V. The voltage value higher than 0.4V indicates the higher resistance at the
connecting point of the conducting wire.
Tip:
The picture below is only a schematic diagram.
01
02
03
04
05
06
07
08
09
(d). Measure the voltage drop between the housing of the generator and the negative terminal of the
battery with the DC voltage position of the digital multimeter. The normal voltage value shall be no
10 more than 0.3V. The voltage value higher than 0.3V indicates the loose connection of the
conducting wire and the higher resistance at the connecting point.
11 Tip:
The picture below is only a schematic diagram.
12
13
14
4. Test of Single Generator
(a). Measure the conduction of the generator terminal

with an ohm gauge.
Tip: 01
The pointers of the ohm gauge shall be connected with
the two pins of the generator terminal respectively. If the 02
value displayed on the ohm gauge is infinite, the harness
in the generator is disconnected, and the generator is
03
damaged and shall be replaced. If the value displayed on
the ohm gauge is extremely small, the generator harness
is in a good condition. 04
05
06
07
(b). No-Load Test 08

• Switch on the switch K and increase the rotating
speed of the generator slowly. Touch the 09
magnetic field terminal of the generator with the
positive wire of the battery to excite the
10
generator. When the terminal voltage of the
generator reaches 18V, the rotating speed of the
generator shall be 1000r/min. 11
Tip:
The manual rotation of generator shall be flexible without 12
clamping stagnation and scraping.
13
14
(c). Load Test

• Adjust the load resistance in the circuit to the
maximum.
• Switch off the switch when the AC generator
voltage in the no-load test reaches 28V to induce
the generator to output current.
• Gradually reduce the load resistance to increase
the output current. Maintain the terminal voltage
of the generator at 28V by means of increasing
the rotating speed. The displayed value shall
meet the requirements of the following table.
Output Terminal Voltage Rotating Speed of

Current/A of Generator/V Generator /(r/min)
5 28 <1300
23 28 <1400
Removal and Installation of Generator

1. Shutdown Vehicle Stably and Switch Off Ignition Switch
01
2. Disconnect Battery Pole Lead
(a). Break the dustproof adhesive tape of the battery pole
02 lead.
(b). Unscrew the fixing bolt for the battery pole lead.
03 (c). Rock leftwards and rightwards to take out the battery
pole lead.
04 Caution:
While removing pole leads, the negative pole of power
05 must be removed prior to removing other pole lead.
06
(d). Pull out the positive pole lead of the battery.
07
08
09
10
11
3. Remove Generator
12 (a). Cut through the strapping tape for the harness of
generator.
13
14
(b). Disconnect the connector of generator.

(c). Remove the output terminal harness of generator.
01
02
03
04
(d). Loosen the adjusting bolts for the generator upper
support. 05
Tip:
While removing the generator upper support, loosen the
06
adjusting bolts on the support firstly, then untie the
generator belt, and remove generator upper support
finally. It is easy to move in such a way. 07
08
09
10
11
12
(e). Push the generator upwards. Remove the generator
belt until it becomes loose.
13
14
(f). Remove the fixing bolt at the lower end of the

generator.
01
02
03
04
05
06
07 (g). Remove the adjusting bolts for the generator upper

support.
08
09
10
11
12
13
14
(h). Remove the generator assembly.

4. Install Generator
(a). Put a good generator in the mounting position of
generator.
01
02
03
04
05
06
(b). Install the fixing bolt at the lower end of generator and 07
screw up the fixing bolts to the standard level.
08
09
10
11
12
13
14
(c). Install the adjusting bolts for the generator upper

support.
Caution:
Don’t screw up the adjusting bolts for the generator
upper support at the moment.
(d). Push the generator upwards and install the generator

belt.
01
02
03
04
05
06
07 (e). Push the generator downwards, tighten the generator

belt to the standard level, and screw up the adjusting
08 bolts for the generator upper support to the standard
level.
09
10
11
12
13
14
(f). Install the output terminal harness of generator.
(g). Connect the harness connector of generator.

(h). Strap the generator harness with the harness

strapping tape.
01
02
03
04
5. Connect Battery Pole Lead
(a). Connect the positive battery lead. 05
06
07
08
09
(b). Sheathe the battery pole lead on the pole.
(c). Screw up the fixing bolt for battery pole lead. 10
(d). Cover the battery bracing dust cover.
11
12
13
14
14-12 Electric Equipment System - Starter
Starter
General
Start refers to the process of converting an engine from the idle state to the operating state. The start of
01 engine must be realized with the help of external force, and starter is a device for converting an engine
from the idle state to the operating state.
02
03
04
05
06
07
08
09
10
11
12
13
14
Electric Equipment System - Starter 14-13
Part Drawing
01
02
03
04
05
06
07
08
09
10
11
12
13
14
1 Starter Bolt 3 Starter Assembly

2 Starter Bolt
Starter Test
1. Voltage Drop Test of Starting System
The voltage drop test is mainly used for inspecting the connecting conditions of the conducting wires of
the starter main circuit. The voltage shall be measured with the DC voltage position of a digital
01
multimeter according to the following picture. The voltage value measured in each position shall be no
more than 0.2V. The measured voltage of ＞0.2V in a certain position indicates that the connecting wire
02 here has certain problem.
03
04
05
06
07
08
09
10
11
12
2. Starter Test
13 The quality of performance and technical conditions of starter shall be judged by the no-load test, brake
test, the performance test of electromagnetic switch, etc.
14 (a). No-Load Test
• Switch on the circuit to observe whether the starter operates normally. Connect the ampere
meter with the circuit in series and read the current value. The current value shall be no more
than 90A.
Caution:
The idling period of starter shall be no more than 1 minute.
01
02
03
04
05
06
07
08
09
(b). Brake (Lock-Rotor) Test
The brake test shall be performed on a starter test bed. The fault of starter internal circuit shall be further
inspected by measuring the torque and consumed current while braking. Furthermore, the slippage of 10
meshing gears can also be inspected. Only the starter passing the no-load test can be used in the brake
test. The test methods are as follows: 11
• Clamp the starter to be tested on the braking 12

clamp of a universal test bed, and clamp the
three teeth on the pinion gear with the clamping 13
block on the brake linkage.
14
• Connect the connecting wires of the test bed and

the starter.
Starter
• Press down the button SB on the universal test

bed (must press down firmly without lifting the
finger) to brake the starter. Read the readings of
01 voltage and current on the dials of the voltmeter
and ampere meter respectively, and read the
02 torque value on the spring scales. Compared the
measured values of voltage, current and torque
with the standard value, and judge whether the
03
starter has any fault or not by analysis.
Caution:
04 The connecting period of circuit shall be no more
than 5s. If another test is required, it is necessary to
05 perform the test after 1~2 minutes of rest for the
battery so as to avoid shortening the service life of
06 the battery.
07 3. Performance Test of Electromagnetic Switch

(a). Remove the connecting wire between terminal M and the electromotor as shown in the picture.
(b). Connect the negative pole of battery with the starter housing and connect the positive pole with
08 terminal S as shown in the picture. At the moment, the armature does not move due to the small
electromagnetic force although the coil is kept electrified.
09 (c). Connect the negative pole with terminal M. A snap for pick-up can be heard inside the
electromagnetic switch, and the driving gear is pushed out.
10 (d). Move the negative pole away from terminal M, and keep the electromagnetic switch picked-up. The
resistance between the two contactors of the electromagnetic switch shall be “0”.
11
12
13
14
Removal and Installation of Starter

1. Disconnect Battery Pole Lead
(a). Break the dustproof adhesive tape of the battery pole
01
lead.
(b). Unscrew the fixing bolt for the battery pole lead.
(c). Rock leftwards and rightwards to take out the battery 02
pole lead.
Caution: 03
While removing pole leads, the negative pole of power
must be removed prior to removing other pole lead. 04
05
(d). Pull out the positive pole lead of the battery.
06
07
08
09
10
2. Remove Starter Assembly

11
(a). Pull out the connecting harness of starter.
12
13
14
(b). Remove the connecting bolt of the starter assembly.
01
02
03
04
05
06
07 (c). Remove the starter assembly carefully.
08
09
10
11
12
13
14
3. Install Starter Assembly

(a). Put a good starter in the mounting position of starter.
(b). Install two fixing bolts for the starter, and screw them
up to the standard level.
01
02
03
04
05
06
(c). Install the connecting harness of the starter. 07
08
09
10
11
12
13
14
4. Connect Battery Pole Lead
(a). Connect positive pole battery lead.
(b). Sheathe the battery pole lead on the pole.

(c). Screw up the fixing bolt for battery pole lead.
(d). Cover the battery bracing dust cover.
- Remark -
01
02
03
04
05
06
07
08
09
10
11
12
13
14

Gasoline Engine

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Gasoline Engine

Uploaded by

Copyright:

Available Formats

Introduction...............................................................................................

How to Use This Manual

Assembly Relationship of Parts

Stud Bolt, for Connection of Exhaust

List of Part Names

Tip and Caution 14

International System of Units (SI)

Vehicle Identification Mark

1 Intake Manifold 9 High Tension Ignition Cable Assembly

1 Driving Pulley 11 High-voltage Ignition Coil Assembly

1 Transmission Assembly 11 Thermostat Assembly

1 Transmission Assembly 13 Belt

General Safety Rules

General Repair Instructions

General Cleaning Instructions

Sanding Abrasive Disc and Paper

06 Solvent and Acid Cleaning

Intake/exhaust valve seat ring To install intake/exhaust valve seat 09

To measure the inner diameter of the

Camshaft timing gear extractor To remove camshaft timing gear

Air inlet resistance watch To measure air inlet pressure

Puller To remove crankshaft pulley

07 Piston pin punch To remove piston pin

Camshaft bearing shell remover To remove camshaft bearing shell

Tachometer To measure engine’s rotational speed

Cylinder pressure gauge components To measure cylinder pressure

Oil seal remover To remove oil seal

Oil seal installer To install oil seal

Piston installer To install piston assembly

Adjustable or watch-hand torque

90-degree angle measurement To measure right-angle 09

Thermometer To test thermostat

Regulatory To measure clearance

To measure the flatness of cylinder or

Dial indicator To measure shaft runout or clearance

To support instruction class (dial

To measure the diameter and

Horizontal jack To lift heavy objects

Scraper To clean residual gasket

02 Combination pliers To remove cotter pin

04 Copper rod To remove gear

Insurance iron bench To withstand the car frame

Large adjustable wrench To use together with the puller

Oil basin and cleaning brush To clean components

Wire brush To clean stains

Oil seal installer To install oil seal

Circlip clamp To remove axis circlip

To beat the weak parts or dismantling

08 Engine lubricating oil To lubricate engine frication parts

09 Valve grinding paste To grind valve and valve seat ring

Thin fuse wire To check the bearing radial clearance

Total Piston Displacement 1.051L +

Firing Order 1-3-4-2 08

Max. Idling Speed 6000r/min 09

Min. Idling Speed 850 ± 50 r/min 10

Fuel Consumption 275/kw.h

Oil Fuel Consumption Ratio <1%

Oil Pressure 294 ~ 490Kpa

Starting Method Electric started

Lubrication Method Pressure and splash compound

Cooling Method Forced circulation water cooling

Net Weight 98kg

Dimensions (L × W × H) 570mm × 613.2mm × 435.9mm